Classification and analysis of the failures occured in ship design and construction using reverse engineering data

Increasing competition in the shipbuilding industry forces shipyards to produce ships cheaper, in shorter time and in increased quality. Therefore shipyards have to continually increase their productivity in order to keep up with the shipbuilding market. Ship design and construction is an intricate process, incorporating various different actors, effects and disciplines that dures months to years. Contrary to mass production, each project is unique (with high privatization) within the scope of owner/authority. In this complex, privatized and long-term project type, the most significant of the seven typical wastes(muda) defined by Taiichi Ohno, the founder of Lean Thinking, is Faulty-Defective Products. Due to reworks and corrective actions owing to errors, a significant amount of labor, material and time losses occur. However, the ideal state is to achieve an error-free process, errors seem to be unavoidable in a such complicated type of production by nature. Under the principle of continuous improvement/pursue of perfection, errors should be prevented as much as possible and/or detected as early as possible. By the effort, shipyard would save a great quantity of time and money. In the thesis, a new evaluation system is introduced inspired by the Failure Mode and Effect Analysis (FMEA) with the name of "Analysis Method with Reverse Engineering Data" in which concrete/realized error data are used. In this method, with the analysis at the end of or during the project, the aim is to determine the errors having great significance and prevent or reduce the frequency in next projects or the rest of the ongoing projects. In the method, a database of the errors that have already occured and reported is created, similar errors are grouped and the Error Priority Number is calculated by the evaluation of the predetermined criteria. The evaluation of EPN, according to different values is defined above: 1. Group Error: 25