The document summarizes the work Arno Paul Scholtz completed at Belmet Marine Manufacturing from June 10-July 7, 2014. He designed a new beam and support structure to upgrade an existing crane. This involved measurements, calculations, CAD modeling, and simulations. When not working on projects, he created drawings for a subcontractor to understand CAD and engineering drawings. Belmet focuses on safety and uses various welding, heating, and testing techniques for high-volume manufacturing of parts for large vessels.
This document is a resume for Jay Brantley summarizing his professional experience in fabrication spanning over 23 years. It details his roles as a plant manager, field fabrication supervisor, estimator, and welding inspector. It also lists his relevant skills, certifications, and licenses including AWS CWI certifications and NCCER welding and safety instructor qualifications. Contact information is provided for 8 professional references.
Sidney Dong is seeking a senior or intermediate piping designer position and has over 10 years of experience as a project designer at Enerflex Ltd. He is proficient in various piping design software and has experience with plant layout, skid design, pressure vessels, and piping for gas processing facilities. He has extensive knowledge of gas processing systems and applies industry standards to achieve cost reductions.
Deepayan Mazumder completed a 60-day internship with Shanta Properties Ltd from November 28, 2015 to February 9, 2016. During this time, he observed formwork, floor slab casting, and curing practices on the Araddho construction project. He learned that steel formwork has advantages over other materials due to its strength, durability, and ability to be reused. Mazumder also studied how to properly cast floor slabs, including reinforcement and curing methods. His supervisor assessed that Mazumder met expectations in taking responsibility, problem solving, collaboration, and communication. Overall, the internship enhanced Mazumder's construction knowledge.
The document discusses how prefabrication can reduce construction costs and timelines when implemented effectively through integrated project delivery and BIM modeling. It provides examples of how prefabricating electrical components like lighting boxes and panels off-site, rather than building them on-site, can significantly reduce installation times by 10-20% while also improving efficiency and reducing congestion. When used for projects with repetitive components, prefabrication offers substantial labor savings that can increase with the scale of the project.
The document describes the fabrication process of a modular pallet rack for storing completely built motorcycles at Boulos Enterprises Limited in Nigeria. Key aspects include:
1) The project was implemented in two phases, with the first phase lacking proper management tools resulting in dimensional inaccuracies. The second phase introduced modularization and welding fixtures to improve accuracy.
2) A work breakdown structure divided the project into modules, fixture fabrication, module fabrication, assembly, additions and finishing.
3) Safety considerations like personal protective equipment and ventilation were followed to protect workers during fabrication.
This document discusses a turbine case study involving the PowerCo company. PowerCo initiated the Turbine project to develop a more competitive steam turbine as the market was declining and their turbines lagged competitors' in efficiency. The project involved multi-disciplinary teams from areas like aerodynamics and mechanical integrity working to increase efficiency while controlling costs. It pushed boundaries by developing the longest rotor blades ever and considering new materials like titanium. Successfully integrating knowledge across disciplines and developing new technologies was challenging due to uncertainties and limited validation of modeling tools.
This document summarizes the experience and skills of an individual with over 8 years of experience in design and product development for the aerospace and automotive industries. They have expertise in CATIA V5 modeling and have worked on projects involving design, manufacturing, assembly design, and reverse engineering for clients such as Ashok Leyland and PSB Pune. Their experience includes design of components for aircraft engines, vehicle chassis, and automotive seating and airbag subassemblies.
Craig Millar has over 15 years of experience in wind turbine blade manufacturing, service, maintenance, and quality control. He has held various roles including process engineer, engineering technician supervisor, group trainer, and composite consultant. Millar has extensive knowledge of composite engineering and manufacturing processes related to wind turbine blades.
This document is a resume for Jay Brantley summarizing his professional experience in fabrication spanning over 23 years. It details his roles as a plant manager, field fabrication supervisor, estimator, and welding inspector. It also lists his relevant skills, certifications, and licenses including AWS CWI certifications and NCCER welding and safety instructor qualifications. Contact information is provided for 8 professional references.
Sidney Dong is seeking a senior or intermediate piping designer position and has over 10 years of experience as a project designer at Enerflex Ltd. He is proficient in various piping design software and has experience with plant layout, skid design, pressure vessels, and piping for gas processing facilities. He has extensive knowledge of gas processing systems and applies industry standards to achieve cost reductions.
Deepayan Mazumder completed a 60-day internship with Shanta Properties Ltd from November 28, 2015 to February 9, 2016. During this time, he observed formwork, floor slab casting, and curing practices on the Araddho construction project. He learned that steel formwork has advantages over other materials due to its strength, durability, and ability to be reused. Mazumder also studied how to properly cast floor slabs, including reinforcement and curing methods. His supervisor assessed that Mazumder met expectations in taking responsibility, problem solving, collaboration, and communication. Overall, the internship enhanced Mazumder's construction knowledge.
The document discusses how prefabrication can reduce construction costs and timelines when implemented effectively through integrated project delivery and BIM modeling. It provides examples of how prefabricating electrical components like lighting boxes and panels off-site, rather than building them on-site, can significantly reduce installation times by 10-20% while also improving efficiency and reducing congestion. When used for projects with repetitive components, prefabrication offers substantial labor savings that can increase with the scale of the project.
The document describes the fabrication process of a modular pallet rack for storing completely built motorcycles at Boulos Enterprises Limited in Nigeria. Key aspects include:
1) The project was implemented in two phases, with the first phase lacking proper management tools resulting in dimensional inaccuracies. The second phase introduced modularization and welding fixtures to improve accuracy.
2) A work breakdown structure divided the project into modules, fixture fabrication, module fabrication, assembly, additions and finishing.
3) Safety considerations like personal protective equipment and ventilation were followed to protect workers during fabrication.
This document discusses a turbine case study involving the PowerCo company. PowerCo initiated the Turbine project to develop a more competitive steam turbine as the market was declining and their turbines lagged competitors' in efficiency. The project involved multi-disciplinary teams from areas like aerodynamics and mechanical integrity working to increase efficiency while controlling costs. It pushed boundaries by developing the longest rotor blades ever and considering new materials like titanium. Successfully integrating knowledge across disciplines and developing new technologies was challenging due to uncertainties and limited validation of modeling tools.
This document summarizes the experience and skills of an individual with over 8 years of experience in design and product development for the aerospace and automotive industries. They have expertise in CATIA V5 modeling and have worked on projects involving design, manufacturing, assembly design, and reverse engineering for clients such as Ashok Leyland and PSB Pune. Their experience includes design of components for aircraft engines, vehicle chassis, and automotive seating and airbag subassemblies.
Craig Millar has over 15 years of experience in wind turbine blade manufacturing, service, maintenance, and quality control. He has held various roles including process engineer, engineering technician supervisor, group trainer, and composite consultant. Millar has extensive knowledge of composite engineering and manufacturing processes related to wind turbine blades.
Manufacturing engineers design production processes to increase efficiency and lower costs. For example, Henry Ford's assembly line reduced the time to assemble a Model T car from 12.5 hours to 6 hours using specialized work stations. It also reduced the number of workers and tools needed. Timelines for manufacturing projects can range from a few months to overhaul an existing process to avoid a costly recall. Costs vary depending on the scale of the project, but large projects can cost millions. The end goal is to continually improve production through the work of manufacturing engineers, making goods more accessible to the public.
The team of ten members was tasked with designing a plant to manufacture and assemble hair dryers for use in regional peripheral warehouses, shopping malls, and shops. A well-equipped assembly area, a raw materials warehouse (RMW), a finished product warehouse (FPW), a semi-finished storage area, and service areas have all been available at the plant. Geometric and volumetric sizing, lines and/or cells and/or work departments, shelving, reception areas, shipping areas, picking areas, packaging areas, and finished product containment buildings were all the responsibility of each project team.
Injection molding is commonly used for mass production but 3D printing is used for prototypes. PolyJet 3D printing allows for injection molds to be created in 1-2 days for under $1,400, much faster and cheaper than metal molds. This allows companies to test designs and materials earlier using actual production materials. German company Seuffer used a PolyJet mold to test a complex part in one day for less than $1,400, validating the design much faster and cheaper than possible with metal molds.
3D printing can be used to create customized prosthetics and implants directly from patient scan data, allowing for a better fit. It is also used in the aerospace and automotive industries to create detailed physical models for design verification before manufacturing. For example, a generator company used 3D printing to create internal component models to check fit and identify issues early. A car company also used it to build a complex gearbox housing model quickly to verify their CAD design.
Difference between DFM, DFA, DFMA with good explanationManiKandan214178
The document discusses design for manufacturing and assembly (DFMA). It describes how Boothroyd and Dewhurst pioneered work on DFMA in the 1970s by analyzing existing product designs and developing guidelines to improve designs based on manufacturing and assembly ease. Their methods evaluate assembly efficiency and identify opportunities to reduce part count, simplify assembly operations, and make designs more amenable to different assembly methods like manual, robotic, or high-speed automated assembly. The document provides examples of applying DFMA principles and guidelines to redesign products for improved assembly efficiency.
Jason Dixon is a degree qualified project manager with over 20 years of experience managing international commercial projects. He has experience leading teams and running complex, multi-million pound projects in industries such as offshore equipment, material handling, steel processing, and aviation. His background includes improving project execution processes, developing teams, and completing projects on time and on budget.
This document discusses concrete block production challenges in Columbia. It notes that there is little technical information available to concrete block producers in Columbia. It identifies 12 key variables that can impact concrete block quality, including aggregates, cement, mix design, production process, curing, and additives. It provides details on each of these variables and stresses the importance of understanding production standards and regulations to ensure high quality blocks. Overall, the document aims to provide producers in Columbia with guidance to help overcome basic problems in concrete block manufacturing.
Webinar #15 - Sharing Your Bill of Materials, Who Gets What Oleg Shilovitsky
BOM contains all the information about the product. But how do we present meaningful information to specific Roles? What data can be shared and how to access it based on roles.
The document discusses additive manufacturing (AM) techniques like direct metal laser sintering (DMLS) and selective laser sintering (SLS). It describes how AM works by building 3D objects layer by layer from a digital model. The document outlines various AM techniques, materials used, industries adopting AM, benefits like reduced tooling and weight optimization, limitations like large volume production issues. It provides examples of companies like EOS that manufacture AM equipment and cost illustrations. Application examples discussed are aerospace parts, potential aero engine parts, and the outlook for AM.
Design and Engineering Module 3: Prototype to ProductNaseel Ibnu Azeez
As per KTU Syllabus Design and Engineering
Prototyping- rapid prototyping; testing and evaluation of design; Design modifications; Freezing the design; Cost analysis. Engineering the design – From prototype to product.
Planning; Scheduling; Supply chains; inventory; handling; manufacturing/construction operations; storage; packaging; shipping; marketing; feed-back on design.
T. Luoma_project_engineer_Instrumentation_Automation_controlsTero Luoma
Tero Luoma is a Finnish project engineer with over 10 years of experience in the oil and gas industry. He has a BSc in automation and controls engineering and is skilled in AutoCAD, various industry codes and standards, and COMPEX certification. Luoma has worked on projects for several companies involving instrumentation, controls systems, and electrical equipment design, installation and upgrades. He is looking for a new position that offers opportunities for technology development.
- Abdallah Bayoumi Mohammed Ibrahim is a senior estimation and proposal engineer with over 9 years of experience in EPC tendering and project management for energy, industrial, and oil & gas projects in the Middle East.
- He has a Bachelor's degree in Mechanical Engineering and qualifications in business development, project scheduling, cost control, and risk management.
- His previous roles include positions as a head of estimation and proposals, proposal engineer, and manufacturing engineer for companies in Egypt, Qatar, and the UAE working on projects such as power plants, refineries, pipelines and more.
This document discusses construction take-off software. It provides an overview of the purpose of construction take-off in estimating project costs. Traditionally, take-offs were done by hand using blueprints, rulers and calculators. Now, contractors can use specialized software to simplify and improve the take-off process. The document then discusses specific take-off software programs, their features, costs, advantages and disadvantages compared to doing take-offs manually or in Excel. Integrated Autodesk programs are highlighted as providing precise results and tools, but requiring training and regular updates.
MINIATURIZED CYLINDER HEAD PRODUCTION BY RAPID PROTOTYPINGRodrigo Melo
Abstract. This work shows the development of the design and manufacturing of a very small engine, namely its head.
The engine works under the 4-stroke cycle, therefore having a very complex cylinder head, housing the camshaft,
valves and its auxiliaries (seats, guides, springs), spark plug, inlet and exhaust passages and a coolant chamber. The
geometries, both inner and outer are highly intricate which makes the production of such a part a very difficult job. In
addition, when the engine is very small, as it is the case of this engine, all dimensions are miniaturized therefore
making it extremely difficult to design, cast and finish. The cooling chamber, in particular, has a critical inner core
removal problem due to reduced accessibility, imposing casting limitations. The cores place also a problem of air and
gas removal during metal filling and solidification. Rapid prototyping may be the only solution to build the cores, and
may help in the design and manufacturing phases of the casting tools. 3D printing with a plaster based material as a
rapid prototyping technique presents itself as a tool to drastically reduce the design-development-casting process effort
and time cycle. This technique enables the designer to obtain new moulds for castings on the shortest time possible,
following redesign and new casting simulations. This paper illustrates the various tasks involved in the design and
development stages leading to the production of a running prototype of the cylinder head for this small engine.
Moghe Amol Sukumar is a senior design engineer with over 5 years of experience in the railway and automobile domains. He has extensive experience using CATIA V5 for part, sheet metal, and assembly design. Some of his responsibilities include designing rail components, sheet metal forming and joining processes, application of GD&T, and creating documentation like drawings and bills of materials. He has worked on projects for Bombardier Transportation in Canada involving the design of sidewalls, interior linings, and undercarriage components for monorail vehicles. He is proficient in CAD tools like CATIA V5 and PDM/PLM systems like Enovia 3D COM.
Lead Aircraft Design/Compliance Checker EngineerLen Jones
I am a very experienced Drawing Checker (Geometric Tolerancing and Fit & Function,
to BS 8888 and ISO 9001), Project Engineer/Manager, and Compliance Engineer in the Civil, Defence, and MoD disciplines.
Now available 'immediately' on signing and acceptance of agreed Contract.
The document discusses making adjustments to a project plan and schedule to ensure the project is completed on time. It recommends several strategies: having workers work overtime, prioritizing dependent tasks, reassigning incompetent resources, adding more resources to critical tasks, and reallocating resources from less demanding to more critical tasks. The overall goal is to use these approaches to finish the project within the stipulated four month timeframe.
A Review: Fused Deposition Modeling – A Rapid Prototyping ProcessIRJET Journal
This document provides an overview of fused deposition modeling (FDM), a rapid prototyping process. FDM involves layer-by-layer deposition of thermoplastic materials using an extrusion nozzle to build 3D parts from CAD data. Key aspects covered include:
- The FDM process involves heating and extruding plastic filaments through a nozzle to build parts layer-by-layer.
- Common thermoplastics used include ABS and PLA, and process parameters like orientation, layer thickness, and raster width impact part quality.
- FDM can produce functional prototypes and has applications in industries like aerospace, consumer goods, and automotive for prototyping, tooling, and low-volume production
Manufacturing engineers design production processes to increase efficiency and lower costs. For example, Henry Ford's assembly line reduced the time to assemble a Model T car from 12.5 hours to 6 hours using specialized work stations. It also reduced the number of workers and tools needed. Timelines for manufacturing projects can range from a few months to overhaul an existing process to avoid a costly recall. Costs vary depending on the scale of the project, but large projects can cost millions. The end goal is to continually improve production through the work of manufacturing engineers, making goods more accessible to the public.
The team of ten members was tasked with designing a plant to manufacture and assemble hair dryers for use in regional peripheral warehouses, shopping malls, and shops. A well-equipped assembly area, a raw materials warehouse (RMW), a finished product warehouse (FPW), a semi-finished storage area, and service areas have all been available at the plant. Geometric and volumetric sizing, lines and/or cells and/or work departments, shelving, reception areas, shipping areas, picking areas, packaging areas, and finished product containment buildings were all the responsibility of each project team.
Injection molding is commonly used for mass production but 3D printing is used for prototypes. PolyJet 3D printing allows for injection molds to be created in 1-2 days for under $1,400, much faster and cheaper than metal molds. This allows companies to test designs and materials earlier using actual production materials. German company Seuffer used a PolyJet mold to test a complex part in one day for less than $1,400, validating the design much faster and cheaper than possible with metal molds.
3D printing can be used to create customized prosthetics and implants directly from patient scan data, allowing for a better fit. It is also used in the aerospace and automotive industries to create detailed physical models for design verification before manufacturing. For example, a generator company used 3D printing to create internal component models to check fit and identify issues early. A car company also used it to build a complex gearbox housing model quickly to verify their CAD design.
Difference between DFM, DFA, DFMA with good explanationManiKandan214178
The document discusses design for manufacturing and assembly (DFMA). It describes how Boothroyd and Dewhurst pioneered work on DFMA in the 1970s by analyzing existing product designs and developing guidelines to improve designs based on manufacturing and assembly ease. Their methods evaluate assembly efficiency and identify opportunities to reduce part count, simplify assembly operations, and make designs more amenable to different assembly methods like manual, robotic, or high-speed automated assembly. The document provides examples of applying DFMA principles and guidelines to redesign products for improved assembly efficiency.
Jason Dixon is a degree qualified project manager with over 20 years of experience managing international commercial projects. He has experience leading teams and running complex, multi-million pound projects in industries such as offshore equipment, material handling, steel processing, and aviation. His background includes improving project execution processes, developing teams, and completing projects on time and on budget.
This document discusses concrete block production challenges in Columbia. It notes that there is little technical information available to concrete block producers in Columbia. It identifies 12 key variables that can impact concrete block quality, including aggregates, cement, mix design, production process, curing, and additives. It provides details on each of these variables and stresses the importance of understanding production standards and regulations to ensure high quality blocks. Overall, the document aims to provide producers in Columbia with guidance to help overcome basic problems in concrete block manufacturing.
Webinar #15 - Sharing Your Bill of Materials, Who Gets What Oleg Shilovitsky
BOM contains all the information about the product. But how do we present meaningful information to specific Roles? What data can be shared and how to access it based on roles.
The document discusses additive manufacturing (AM) techniques like direct metal laser sintering (DMLS) and selective laser sintering (SLS). It describes how AM works by building 3D objects layer by layer from a digital model. The document outlines various AM techniques, materials used, industries adopting AM, benefits like reduced tooling and weight optimization, limitations like large volume production issues. It provides examples of companies like EOS that manufacture AM equipment and cost illustrations. Application examples discussed are aerospace parts, potential aero engine parts, and the outlook for AM.
Design and Engineering Module 3: Prototype to ProductNaseel Ibnu Azeez
As per KTU Syllabus Design and Engineering
Prototyping- rapid prototyping; testing and evaluation of design; Design modifications; Freezing the design; Cost analysis. Engineering the design – From prototype to product.
Planning; Scheduling; Supply chains; inventory; handling; manufacturing/construction operations; storage; packaging; shipping; marketing; feed-back on design.
T. Luoma_project_engineer_Instrumentation_Automation_controlsTero Luoma
Tero Luoma is a Finnish project engineer with over 10 years of experience in the oil and gas industry. He has a BSc in automation and controls engineering and is skilled in AutoCAD, various industry codes and standards, and COMPEX certification. Luoma has worked on projects for several companies involving instrumentation, controls systems, and electrical equipment design, installation and upgrades. He is looking for a new position that offers opportunities for technology development.
- Abdallah Bayoumi Mohammed Ibrahim is a senior estimation and proposal engineer with over 9 years of experience in EPC tendering and project management for energy, industrial, and oil & gas projects in the Middle East.
- He has a Bachelor's degree in Mechanical Engineering and qualifications in business development, project scheduling, cost control, and risk management.
- His previous roles include positions as a head of estimation and proposals, proposal engineer, and manufacturing engineer for companies in Egypt, Qatar, and the UAE working on projects such as power plants, refineries, pipelines and more.
This document discusses construction take-off software. It provides an overview of the purpose of construction take-off in estimating project costs. Traditionally, take-offs were done by hand using blueprints, rulers and calculators. Now, contractors can use specialized software to simplify and improve the take-off process. The document then discusses specific take-off software programs, their features, costs, advantages and disadvantages compared to doing take-offs manually or in Excel. Integrated Autodesk programs are highlighted as providing precise results and tools, but requiring training and regular updates.
MINIATURIZED CYLINDER HEAD PRODUCTION BY RAPID PROTOTYPINGRodrigo Melo
Abstract. This work shows the development of the design and manufacturing of a very small engine, namely its head.
The engine works under the 4-stroke cycle, therefore having a very complex cylinder head, housing the camshaft,
valves and its auxiliaries (seats, guides, springs), spark plug, inlet and exhaust passages and a coolant chamber. The
geometries, both inner and outer are highly intricate which makes the production of such a part a very difficult job. In
addition, when the engine is very small, as it is the case of this engine, all dimensions are miniaturized therefore
making it extremely difficult to design, cast and finish. The cooling chamber, in particular, has a critical inner core
removal problem due to reduced accessibility, imposing casting limitations. The cores place also a problem of air and
gas removal during metal filling and solidification. Rapid prototyping may be the only solution to build the cores, and
may help in the design and manufacturing phases of the casting tools. 3D printing with a plaster based material as a
rapid prototyping technique presents itself as a tool to drastically reduce the design-development-casting process effort
and time cycle. This technique enables the designer to obtain new moulds for castings on the shortest time possible,
following redesign and new casting simulations. This paper illustrates the various tasks involved in the design and
development stages leading to the production of a running prototype of the cylinder head for this small engine.
Moghe Amol Sukumar is a senior design engineer with over 5 years of experience in the railway and automobile domains. He has extensive experience using CATIA V5 for part, sheet metal, and assembly design. Some of his responsibilities include designing rail components, sheet metal forming and joining processes, application of GD&T, and creating documentation like drawings and bills of materials. He has worked on projects for Bombardier Transportation in Canada involving the design of sidewalls, interior linings, and undercarriage components for monorail vehicles. He is proficient in CAD tools like CATIA V5 and PDM/PLM systems like Enovia 3D COM.
Lead Aircraft Design/Compliance Checker EngineerLen Jones
I am a very experienced Drawing Checker (Geometric Tolerancing and Fit & Function,
to BS 8888 and ISO 9001), Project Engineer/Manager, and Compliance Engineer in the Civil, Defence, and MoD disciplines.
Now available 'immediately' on signing and acceptance of agreed Contract.
The document discusses making adjustments to a project plan and schedule to ensure the project is completed on time. It recommends several strategies: having workers work overtime, prioritizing dependent tasks, reassigning incompetent resources, adding more resources to critical tasks, and reallocating resources from less demanding to more critical tasks. The overall goal is to use these approaches to finish the project within the stipulated four month timeframe.
A Review: Fused Deposition Modeling – A Rapid Prototyping ProcessIRJET Journal
This document provides an overview of fused deposition modeling (FDM), a rapid prototyping process. FDM involves layer-by-layer deposition of thermoplastic materials using an extrusion nozzle to build 3D parts from CAD data. Key aspects covered include:
- The FDM process involves heating and extruding plastic filaments through a nozzle to build parts layer-by-layer.
- Common thermoplastics used include ABS and PLA, and process parameters like orientation, layer thickness, and raster width impact part quality.
- FDM can produce functional prototypes and has applications in industries like aerospace, consumer goods, and automotive for prototyping, tooling, and low-volume production
2. Technical summary
Work done for Belmet Marine Manufacturing – Arno Paul Scholtz (16998308)
BELMET uses many cranes around their manufacturing plant, but in their medium workshop the JIB
cranes have become insufficient for the weight of most projects undertaken by them. These existing
cranes are all rated for 500kg. There is a JIB crane on the outside of this workshop that is not being
used. The hoist is rated for 2000kg, but the beam of the crane is only rated to 500kg, like the inside
cranes. Therefore BELMET required me to design a beam and support structure in order to move the
outside hoist to the inside of the workshop, while using the least amount of space.
Firstly, it was necessary to take measurements of the existing structural support and layout of the
workshop.Some elementary calculations were done by hand in order to decide on dimensions for the
new crane. Many different support structures and beam designs were considered in order to achieve
the requirementssetoutbyBELMET (dimensional limits,capacity,safetyfactor,etc). The chosen design
was thatof a supportstructure in the formof an H-Beamwithplatesweldedonthe edgesof its flanges.
The beam designisthatof an I-Beamwithatriangularsupportonthe topflange,supportedbyfourteen
ribs, spaced over the length of the 4.5m beam.
The design was then drawn on SolidWorks 2014 and simulation of the design is still to be done, but
otherprojectshave priority.If the simulation is satisfactory the crane will be manufactured at BELMET.
AlthoughIwasemployedbyBELMET, there were some timesthatBELMET didnot have anywork forme
to do. In those instances I did detail drawings for Design For Manufacture (DFM), a sub-contractor
workingwithinBELMET. These drawingsconsisted mainly of weldments. The exposure to SolidWorks
and the engineering drawings used by DFMgave me a deeper understanding of the CAD program and
how to interpret and read the drawings of other engineers.
Belmet has standardized a few layouts and dimensioning practices in order for the workshop to best
utilize the drawings. For instance, when a V-butt weld is to be done, it is broken up into two parts on
the drawings, which is not strictly correct. These two parts are the chamfers and the weld bead
specifications. Thismakesiteasierforthe floorstaff tocomplete projects,because the boilermaker can
cut out the material,agrindercan create the chamferand all that the welderneedstodois weld up the
entire part.
BelmetusesmostlyMIGwelding,forhighvolumeapplications.Andbecause of the highvolume,mostof
the welding that is done by Belmet needs some sort or form of heat treatment. Induction heating
blanketsare usedin some instances to prevent warping and formation of residual stresses. Post weld
heattreatment(PWHT) isalsousedto relieve residualstresses and some parts must be clamped down,
welded and then heat treated in order to insure dimensional accuracy.
An independentcontractorisneededto do material tests on most parts manufactured by Belmet, as is
requested by the client companies. Akram Consulting is responsible for the Non-Destructive Testing
(NDT) of Belmet.Impact,tensile and material composition test are done and they can be rather costly.
3. Non-Technical summary
Work done for Belmet Marine Manufacturing – Arno Paul Scholtz (16998308)
Belmethad a strongemphasisonsafetyandthe use of PPE (Personal ProtectionEquipment). Unlike my
previousworkatEskom,the work I didat Belmetwasmore office basedand not as technical. I felt that
this was a better representation of a professional engineer.
While workingforBelmetIhadexposure to setting up quotes. To create these documents, mainly the
Bill of Materials is needed, and from it most other costs can be determined. It also includes costs
associatedwithtransportandthe likesthereof. Itisnecessarytoknow how much material tosupply for
a project. Thiscan be determinedfromthe Bill of Materialsfoundondrawings. These tablesfrequently
have errorson themand therefore itisnecessarytocheckthat the quantity and dimensions are correct
before an order is placed. Failing to detect errors can cost a company a lot of money. The BOMalso
containspart quantities,like the numberof bolts needed. All of these parts have to be counted and/or
purchased. Material totals are calculated by adding around 10-20% wastage, dependant on the nature
of the project, to the amount needed and then finding the closest standard sizes available.
Labour costs are determined by the total weight of a project. A time estimate per ton is used to
calculate the total man hours needed. From there boilermaker, welder, cleaners and other personnel
costs can be calculated. A companyoverheadisaddedtothe amount(thisisa cost due to things like an
electricitybill thatcannotbe measuredperproject,butis necessaryformanufacture.) anda percentage
is used as a markup to achieve a profit for the company.
A purchase order (PO) is the first official document between a buyer and a seller. It is a contract
between companies that have agreed on the cost of a product to be manufactured/delivered.
On big projects, such as those that Belmet do, time management and resource allocation is very
important. BelmetusesaprogramnamedMicrosoftProjectto set up a timeline, and see just how well
they are conforming to schedule. Some clients also request that frequently updated progress reports
and photosof parts be senton, to ensure timelycompletionof theirprojects. If notcompletedon time,
bothBelmetandthe clientcompanystandto lose a lotof money.This isespeciallytrue whenadry-dock
isneeded. There isusuallyalsoapenaltyfee payable perdaythata projectis late,whichisstipulatedin
the contractual agreement.
The National Union of Metal Workers South Africa started a strike on 01/07/2014. Numsa at first
demanded a12% wage increase andcompanies were offering 7% for skilled workers and 8% for lower-
level workers. Onthe seconddayof the strike Numsademanded15%. Itwasalso demandingthatlabour
brokersbe banned. If the issue is not resolved quickly, it could lead to considerable economic losses.
Some metal suppliers have only up to twelve days of stock left on 01/07/2014. NUMSA consists of
around200 000 members,butdue tointimidationalotmore metal workersdonot go to work in fear of
their safety. BELMET has taken some precautions, urging its employees to make use of their own
transportand movingitsparkingareato the storage lot,increasing safety. ADT (a security company for
BELMET) have a regular presence on the premises and are on standby should something happen. All
doors are kept closed and safety is added by the use of RFID tags, recently introduce by BELMET.