Study On Block Making Flow-line Management For The Shipyard Based On The Theory Of Constraints

Block making has become the constraint for the shipyards' efficient production under the condition of ample order and short docking period. Most of the shipyards would rather find much more subcontractors than improve their own production capacity. The efficiency and the cycle of the jig are the key for expanding production capacity and the constraint of block making. Block making flow-line management has significance for conducting the production for reducing the blocks' supply influence for the whole ship construction and increasing the shipyard's competitive strength.This paper points out the several main reasons for bringing down the output of the block making through giving an in-depth analysis of the China shipping Jiangsu shipyard's block flow-line management based on the theory of constraints. Besides, it proposed several methods such as forward quality control, DBR management for the component, steel plates' miniature inventory management, and lean management of the block making operational cost and so on base on the rate of throughput, inventory and operational costs to relax this constraint so as to get a higher rate of block making throughput.First of all, the source of the topic, the research object and significance are expounded and the research status of the block making flow line management in the domestic and international are summed up. Further, the statuses of the block making in China Shipping Industry Jiangsu shipbuilding base are introduced and the necessities of the block making flow line management are proposed. Secondly, the fundamental principle of the TOC and the applications of five steps focus method are introduced, including think process analysis, distribution analysis, and the model of DBR production management. Again, the constraints of block making flow line about China Shipping Industry Jiangsu Shipbuilding base are summed up through sorting out its block making process based on the theory of constraints. These constraints mainly include the low rate of throughput of block making, the chaos of block precast member distribution, the steel plate inventory management and the production high operating expenses of the block making. Once again, take an in-depth analysis on these constraints through the relevant methods provided by the theory of constraints and put forward corresponding measures on these main constraints. In order to get the high rates of throughput of block making, paper takes the organization's adjustment and forward quality control measures for block making. Take the steps of block precast members' DBR management, the transform of the employment model, the combination of the distribution and quality control to achieve the efficient management of block precast members. Take the steps of the steel plates' first in first out management, steel plates' prediction of usage and purchase to achieve the steel plates' miniature inventory management. Take the steps of the 5S management in the production site and reasonable control of the production supplies to achieve the lean management of block making operational cost. Besides, the implement effect of 64000 T bulk carrier vessels' block making flow line in China Shipping Industry Jiangsu shipbuilding base will be test after the corresponding measures have been implemented for a long time. The paper provides the block making flow line solutions of the straight block, curved block and superstructure and mast house block etcetera according to the current existing block making site and supporting equipment and the characteristics of 64000 T bulk carrier vessels' block making to achieve the production of the whole ship's block making flow line. At last, the evaluation of implementation effect on the block making flow line will be given and summed up the problems which happened in the process to put forward the direction of optimization for the inadequacies of the paper.