Ref: No.

SIT/Internship-13/11

Internship Report
Dawood College of Engineering and Technology, Karachi
Department Of: Industrial Engineering and Management

Muhammad Ehsan D-08-IND-314 Submission Date: 15/03/2011

Copy to: 1. DGM (HRD) 2. GM (Q. C) 3. D.Sp (S. B Hall)

Shahid Ali D-08-IND-337

Muhammad Owais D-08-IND-336

4. College (Chairman IND Department)

cknowledgment
By the Grace of Almighty Allah, We have been able to complete our INTERNSHIP at Karachi Shipyard and Engineering Works. All this become possible only due to the support of the following employees. They help us in understanding the different work being carried out in KS & EW, to enhance our technical skills. We really believe that our internship at KS & EW would never be possible without the support of all these people. We also appreciate the cordial co-operation from all our concern Managers in all departments; Especially:

Lt Cdr Mola Madad PN DGM (HRD)

Mr. M. A Wadood Q. C Supervisor (UT)

Mr. Abdul Majid Billoo GM (Q. C)

Mr. Irfan Ahmed Q. C Supervisor (UT)

Mr. Ghufran Ashraf ASP (NDT)

Mr. Rashid Riaz Q. C Supervisor (MPT)

Mr. Qutubuddin Bhatti (Q .C Officer Hull)

Mr.Obaid-ur-Rahman Q. C Supervisor (RT)

Mr. Zeeshan Aziz Q. C Supervisor

Mr. Abdul Rahman D.Sp (Ship-Building Hall)

S. No. #

Department #

Page No. #

1.

Introduction to KS&EW

4 to 6

2.

Quality Control

Shipbuilding Quality Control (SQC)

Ship Repair Quality Control (SRQC)

7 to 22

Engineering Quality Control (EQC)

Quality Assurance

3.

Ship Building Hall

23 to 25

4.

Conclusion

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Introduction to K S & E W:
The Karachi Shipyard & Engineering Works Limited (KSEW), is Situated at West Wharf in Karachi, Sindh Pakistan. KSEW was established in early 1950's as a project of PIDC. It was incorporated as a public limited company in 1957. The shipyard spread over an area of 29 hectares (71 acres). Karachi Shipyard is the oldest Heavy Engineering Works of Pakistan which is catering for its Ship Building, Ship Repairing, Submarine/Warship Construction and Heavy/General Engineering requirements. KSEW has a large Ship Building Hall, three Ship Building Berths, two Dry Docks, three Foundries (Iron, Steel & Non-Ferrous), Fabrication Shops, one machine shop and other supporting facilities like Carpentry, Pipe Fitting and Light Steel Fabrication Shop. KSEW is working as an autonomous commercial organization under the Ministry of Defense, Government of Pakistan. Karachi Shipyard is the only shipbuilding company in Pakistan. It has built numerous cargo ships, tugboats and support vessels, naval vesselsand submarines. It has played a historical role in transferring of technologies and broadening the industrial base of the country. KSEW is the only shipyard in Pakistan and has two dry docks of 18,000 TDW (Tons Dead Weight) and 26,000 TDW capacities respectively. It has the capability for building large vessels including Cargo Ships, Oil Carriers, Bulk Carriers and Warships, and Marine Craft including Tugs, Barges, Ferries, Fishing Trawlers, Dredgers and Special Crafts. Furthermore, KSEW has the facilities to produce a wide range of heavy engineering products including Heavy Steel Structures, Pressure Vessels, LPG Storage Tanks, Industrial Boilers, Overhead and Portal Cranes, complete Sugar and Cement Plants, etc.

Since 1957 when it commenced its commercial production, it has built over 430 vessels of different types and sizes for different nations. KSEW possesses an elaborate Ship Repair setup where it has so far repaired over 5000 Vessels, both of national as well as foreign origin. Many renowned Navies of the world including Pakistan Navy and various Shipping lines and Port authorities are KSEW's regular customers.

KSEW has experience in handling a wide variety of steel construction work. Power house building / Boiler structure, pedestrian overhead bridge, steel frame buildings, platforms, gantries for cranes, bridges, girders, towers for power transmission, broadcasting and telecommunication etc. are some of the examples. Similarly hydraulic steel work such as sluice, radial, flap, regulator gates, tunnel shafts, penstocks etc. for dams, barrage and headwork is also carried out. KSEW offers complete sugar plants on turnkey basis. So far KSEW has manufactured various plants in the range of capacities from 2000 to 500 TCD which are based on FIVES-CAIL BABCOCK (FCB) FRANCE design. These plants are fully automatic and have the latest technology. KSEW is a major source of supply of steel structures, conveyors, hoppers; bucket elevators, piping, and manganese steel lining plate and cast steel components for kiln, ball mills etc. for the cement factories.

KSEW can rightly be called the first major steel industry of Pakistan ". Although it is designed for series production of ocean going vessels, its role in the support of industry and developmental engineering is very well known and prominent. It has a long record of service to industry and during slump in the shipping industry, has promoted further diversification of its General Engineering activities. It has one of the largest and wellequipped engineering workshops of the country, the foundry (15 metric ton a piece) Steel Foundry (3 metric ton a piece) and Non-Ferrous Foundry (750 Kg. a piece) are working in conformity to ASTM, BSS and DIN norms.

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Quality Control:
Quality control is a process by which entities review the quality of all factors involved in production. This approach places an emphasis on three aspects: Elements such as controls, job management, defined and well managed processes, performance and integrity criteria, and identification of records. Competence, such as knowledge, skills, experience, and qualifications Soft elements, such as personnel integrity, confidence, organizational culture, motivation, team spirit, and quality relationships. The quality of the outputs is at risk if any of these three aspects is deficient in any way. Quality control emphasizes testing of products to uncover defects, and reporting to management who make the decision to allow or deny the release, whereas quality assurance attempts to improve and stabilize production, and associated processes, to avoid, or at least minimize, issues that led to the defects in the first place. For contract work, particularly work awarded by government agencies, quality control issues are among the top reasons for not renewing a contract.

Total quality control:

"Total quality control" is a measure used in cases where, despite statistical quality control techniques or quality improvements implemented, sales decrease. If the original specification does not reflect the correct quality requirements, quality cannot be inspected or manufactured into the product. For instance, the parameters for a pressure vessel should include not only the material and dimensions, but also operating, environmental, safety, reliability and maintainability requirements. The Quality control department of KS&EW ensures the quality of work done, weather it is ship building, ship repairing, or other engineering project. Quality Control department of KS&EW has the following objectives: Carries out inspection and testing related to inspection (during processes and after developing the finish goods) in accordance with the quality plans, procedures, and work instructions and customers requirements. Handles non conforming products Maintain inspection records Maintains and controls the measuring and test equipments and calibrates or arranges for calibration. Co-ordinates with ship design, engineering design departments, ship repair and marketing department for preparing quality plans, and technical procedures & work instructions Closely study the different requirements of the industry and the workers (i-e arrange highly efficient and sophisticated equipments and also fulfill the training requirements of the personnels as well by providing training whenever required).

Quality control department of KS&EW has to maintain the quality of work at the following sections: Shipbuilding Quality Control (SQC) Ship Repair Quality Control (SRQC) Engineering Quality Control (EQC)

Shipbuilding Quality Control (SQC):

Shipbuilding is the construction of ships. It normally takes place in a specialized facility known as a shipyard. Shipbuilders, also called shipwrights, follow a specialized occupation that traces its roots to before recorded history. Shipbuilding and ship repairs, both commercial and military, are referred to as the "naval engineer". The construction of boats is a similar activity called boat building. The dismantling of ships is called ship breaking. In the 20th century, shipbuilding (which encompasses the shipyards, the marine equipment manufacturers, and many related service and knowledge providers) grew as an important and strategic industry in a number of countries around the world. This importance stems from: The large number of skilled workers required directly by the shipyard, along with supporting industries such as steel mills and engine manufacturers; And A nation's need to manufacture and repair its own navy and vessels that support its primary industries.

18th century perspective: 148 ship parts, 18 labeled hull sections (From Cyclopedia, Volume 2, 1728)

Modern shipbuilding manufacturing techniques:

Modern shipbuilding makes considerable use of prefabricated. Entire multi-deck segments of the hull or superstructure will be built elsewhere in the yard, transported to the building dock or slipway, and then lifted into place. This is known as "block construction". The most modern shipyards pre-install equipment, pipes, electrical cables, and any other components within the blocks, to minimize the effort needed to assemble or install components deep within the hull once it is welded together. This was first introduced by Alstom Chantiers de l'Atlantique when they built the largest Ocean Liner in the world Cunard's RMS Queen Mary 2. Ship design work, also called naval architecture, may be conducted using a ship model basin. Modern ships, since roughly 1940, have been produced almost exclusively of welded steel. Early welded steel ships used steels with inadequate fracture toughness, which resulted in some ships suffering catastrophic brittle fracture structural cracks (see problems of the Liberty ship). Since roughly 1950, specialized steels such as ABS Steels with good properties for ship construction have been used. Although it is commonly accepted that modern steel has eliminated brittle fracture in ships, some controversy still exists.[15] Brittle fracture of modern vessels continues to occur from time to time as the use of grade A and grade B steel of unknown toughness or fracture appearance transition temperature (FATT) in way of ships' side shells can be less than adequate for all ambient conditions.

Construction of prefabricated module blocks of HMS Dauntless at BAE'sPortsmouth Shipyard.

Shipbuilding department of KS&EW work continuously to develop and build new ships keeping in view of the requirements of the country and the private firms, giving independent orders. Currently KS&EW are developing or working on a new Ship (F22 Frigate) for Pakistan Navy, with the cooperation of China. The main aim of Shipbuilding Quality Control (SQC) is to check and control the different processes or procedures carry out in the manufacturing of a ship, As shipbuilding demand an accurate, precise and accident free work, so that to minimize the wastages of materials, instruments and tools. QC put efforts to make possible efficient working by proper inspection of equipments, tools, and various tests for materials, so that to use high quality of materials during manufacturing.

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Some important terminologies regarding F22 Frigate ship are:

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 Ship Repair Quality Control (SRQC):

All ships need maintenance and repairs. A part of these jobs must be carried out under the supervision of the Classification Society. A lot of maintenance it is carried out while at sea or in port by ship's staff. However a large number of repair and maintenance works can only be carried out while the ship is out of commercial operation, in a Shiprepair Yard. Prior to undergoing repairs, tankers must dock at a Deballasting Station for if necessary completing the tank cleaning operations and pumping ashore its slops (dirty cleaning water and hydrocarbon residues) ashore. Modern and well-planned facilities exist in KSEW for undertaking above water & under water repairs of Ships and off shore Drilling Rigs. The ancillary facilities include Shore electric supply, Compressed air, Oxygen, Acetylene gas and Natural gas in pipelines and cylinders as well as Fresh and Sea water supply lines and Fire fighting system. The wellequipped Machine Shop is in attendance besides other readily available facilities for supporting Ship repairs of all kind. For above-water repairs of Vessels, Quay Walls of 500 meter on the northern side and 165 meter on the southern side are available. Above water repairs for Vessels of any size and dead weight can be undertaken not only at KSEW premises but also in Karachi Harbour and even at outer anchorage. Similarly any alteration/conversion on hull/ super structure can be undertaken. For marine boilers, insulation, lagging, flooring, brickwork can be carried out at the yard. Facilities also exist for repairs of Steam and Motor Vessels, both Main and Auxiliary machinery and all types of marine and stationary Boilers. Ships having draught of about 20 feet can be accommodated in graving docks, while vessels with draught of up-to 15 feet can be berthed at the quay walls. In the repair or replacement of parts or materials in a ship, QC tries to use high quality materials, therefore reducing risk to a high percent.

Engineering Quality Control (EQC):

The quality check for the all the steel works carried out in KS&EW are properly checked and controlled in EQC. The different manufacturing works carried out consist of developing/manufacturing high pressure vessels, rollers for sugarcane and cement industries, etc........................................................................................................................

In all the above production departments of KS&EW, Quality is checked with the help of the following two main methods: 1. Destructive Testing (DT) 2. Non Destructive Testing (NDT)

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1. Destructive Testing (DT):

In Destructive Testing, tests are carried out to the specimen's failure, in order to understand a specimen's structural performance or material behavior under different loads. These tests are generally much easier to carry out, yield more information, and are easier to interpret than nondestructive testing. Destructive testing is most suitable, and economic, for objects which will be mass produced, as the cost of destroying a small number of specimens is negligible. It is usually not economical to do destructive testing where only one or very few items are to be produced (for example, in the case of a building). Some types of destructive testing:

Stress tests Crash tests Hardness tests Metallographic tests

2. Non Destructive Testing (NDT):

Nondestructive testing or Non-destructive testing (NDT) is a wide group of analysis techniques used in science and industry to evaluate the properties of a material, component or system without causing damage. NDT plays an important role in the quality control of finished goods as well as raw materials. Outside the manufacturing field it is also widely used for routine control of various items during operation to check that whether the quality is detoriated with time or not. Common NDT methods used at KS&EW are: 1. Visual Inspection 2. Magnetic-particle Test (MPT) 3. Dye penetrant Test (DPT) 4. Radiographic Test (RT) 5. Ultrasonic Test (UT)

1. Visual Inspection:
Often overlooked in any listing of NDT methods, Visual Testing inspection is one of the most common and most powerful means of non destructive testing. It is done by observing the test material by naked eye or under a magnifying glass. Other NDT methods such as MPT and DPT are indeed simply scientific ways of enhancing the indication to make it more visible to naked eye. Visual Inspection cannot deduct defects under the surface thats way other methods/tests are performed to ensure the quality of test piece or material.

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2. Magnetic-particle Test (MPT):

Magnetic particle inspection (MPI) is a non-destructive testing (NDT) process for detecting surface and subsurface discontinuities in ferroelectric materials such as iron, nickel, cobalt, and some of their alloys. This method is capable of detecting open source or just below the surface flaws. The process puts a magnetic field into the part. The piece can be magnetized by direct or indirect magnetization. Direct magnetization occurs when the electric current is passed through the test object and a magnetic field is formed in the material. Indirect magnetization occurs when no electric current is passed through the test object, but a magnetic field is applied from an outside source. The magnetic lines of force are perpendicular to the direction of the electric current which may be either alternating current (AC) or some form of direct current (DC). The presence of a surface or subsurface discontinuity in the material allows the magnetic flux to leak. Ferrous iron particles are applied to the part. The particles may be dry or in a wet suspension. If an area of flux leakage is present the particles will be attracted to this area. The particles will build up at the area of leakage and form what is known as an indication. The indication can then be evaluated to determine what it is, what may have caused it, and what action should be taken if any.

3. Dye penetrant Test (DPT):

Dye Penetrant Test (DPT), also called Liquid Penetrant Test (LPT) or Penetrant Testing (PT), is a widely applied and low-cost inspection method used to locate surfacebreaking defects in all non-porous materials (metals, plastics, or ceramics). The penetrant may be applied to all non-ferrous materials and ferrous materials, but for inspection of ferrous components magnetic-particle inspection is also preferred for its subsurface detection capability. LPI is used to detect casting, forging and welding surface defects such as cracks, surface porosities, and leaks in new products, and fatigue cracks on in-service components. First the surface to be test is cleaned with a dry cloth or cotton piece to remove the dust particles. The penetrant usually red in color is applied and allowed to set. The particles of the penetrant get into the cracks on the surface. The surface is cleaned again this putting a small quantity of cleaner on a piece of cloth or cotton and then smoothly cleaning the surface with it. The contrast color usually white is applied on the surface and allowed to

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dry out. This material brings out penetrant red particle from with-in cracks and the white contrast makes it easy to observe.

1. Penetrant application to the Section of material with a surface-breaking crack that is not visible to the naked eye. 2. Excess penetrant is removed. 3. Developer is applied to the surface. 4. Inspection for the presence of discontinuities.

Advantages:
1. The main advantages of DPI are the speed of the test and the low cost. 2. Limited training is required for the operator although experience is quite valuable.

Disadvantages:
1. The main disadvantages are that it only detects surface flaws and it does not work on very rough surfaces. Also, on certain surfaces a great enough color contrast cannot be achieved or the dye will stain the work piece. 2. Proper cleaning is necessary to assure that surface contaminants have been removed and any defects present are clean and dry. Some cleaning methods have been shown to be detrimental to test sensitivity, so acid etching to remove metal smearing and re-open the defect may be necessary.

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4. Radiographic Test (RT):

Radiographic Testing (RT), or Industrial Radiography (IR), is a Non-Destructive Testing (NDT) method of inspecting materials for hidden flaws by using the ability of short wavelength electromagnetic radiation (high energy photons) to penetrate various materials. Either an X-ray machine or a radioactive source (Ir-192, Co-60, or in rare cases Cs-137) can be used as a source of photons. Neutron radiographic testing (NR) is a variant of radiographic testing which uses neutrons instead of photons to penetrate materials. This can see very different things from X-rays, because neutrons can pass with ease through lead and steel but are stopped by plastics, water and oils. Since the amount of radiation emerging from the opposite side of the material can be detected and measured, variations in this amount (or intensity) of radiation are used to determine thickness or composition of material. Penetrating radiations are those restricted to that part of the electromagnetic spectrum of wavelength less than about 10 nanometers. The Radiographic Testing (RT) method is used for the detection of internal flaws in many different materials (especially in joints between materials i-e welding). An appropriate radiographic film is placed behind a test specimen and is exposed by passing either XRays or Gamma-Rays through it. The intensity of the X-Rays or Gamma-Rays while passing through the product is modified according to the internal structure and thickness of the specimen and thus exposed film, after processing, reveals the shadow picture, known as Radiograph of the product. It is then interpreted to obtain data about the flaws present in the specimen. This method is used on wide variety of products such as forgings, castings and weld-ments. Safety: Industrial radiography appears to have one of the worst safety profiles of the radiation professions, possibly because there are many operators using strong gamma sources (> 2 Ci) in remote sites with little supervision when compared with workers within the nuclear indu

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Weld Position: Material: Weld Process: Radiography: Type of Discontinuity:

Flat Steel Arc Welding 145 KV Slag inclusion

5. Ultrasonic Test (UT):

In Ultrasonic Testing (UT) a high frequency sound waves are introduced into the material being inspected. Most ultrasonic inspection is done at frequencies between 0.5 and 20 MHz, Well above the range of human hearing which is about 20 to 20,000 KHz.

The sound waves travel through the material with some attendant loss of energy (attenuation) due to material characteristics. The intensity of sound waves is either measured, after reflection (Pulse Echo) at intensities (or Flaws) or is measured at opposite surface of the specimen (Pulse transmission). The reflected beam is detected and

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analyzed to define the presence and location of flaws. The degree of reflection depends largely on the physical state of matter on the opposite side of the interface, and to a lesser extent on specific physical properties of that matter, for instance, sound waves are almost completely reflected at metal-gas interfaces. Partial reflection occurs at metal liquid or metal solid interfaces. Ultrasonic testing has a superior penetrating power than radiography and can detect flaws deep in the specimen, almost up to 6 to 7 meters of steel. It is quite sensitive to small flaws and allows the precise determination of the location and size of the flaws. Ultrasonic testing is often performed on steel and other metals and alloys, though it can also be used on concrete, wood and composites, albeit with less resolution. It is a form of non-destructive testing used in many industries including aerospace, automotive and other transportation sectors.

Advantages:
1. 2. 3. 4. High penetrating power, which allows the detection of flaws deep in the part. High sensitivity, permitting the detection of extremely small flaws. Only one surface need be accessible. Greater accuracy than other nondestructive methods in determining the depth of internal flaws and the thickness of parts with parallel surfaces. 5. Some capability of estimating the size, orientation, shape and nature of defects. 6. Nonhazardous to operations or to nearby personnel and has no effect on equipment and materials in the vicinity. 7. Capable of portable or highly automated operation.

Disadvantages:
1. Manual operation requires careful attention by experienced technicians 2. Extensive technical knowledge is required for the development of inspection procedures. 3. Parts those are rough, irregular in shape, very small or thin or not homogeneous are difficult to inspect. 4. Surface must be prepared by cleaning and removing loose scale, paint, etc., although paint that is properly bonded to a surface need not be removed. 5. Inspected items must be water resistant, when using water based couplants that do not contain rust inhibitors.

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Quality Assurance:
Quality assurance, or QA for short, is the systematic monitoring and evaluation of the various aspects of a project, service or facility to maximize the probability that minimum standards of quality are being attained by the production process. QA cannot absolutely guarantee the production of quality products. Two principles included in QA are: "Fit for purpose" - the product should be suitable for the intended purpose; and "Right first time" - mistakes should be eliminated. QA includes regulation of the quality of raw materials, assemblies, products and components, services related to production, and management, production and inspection processes.

Works Of QA:
1. The QA department does the following: 2. Monitoring the implementation of Quality Management System through out the organization. 3. Planning and scheduling of internal and external audits. 4. Initializing NCR IQA (Non Conformity Report of Internal Quality Audit). 5. Arranging follow up audit through auditors to verify the implementation and correctiveness of the corrective actions. 6. Planning and scheduling the Quality Council meeting to review. 7. Customers feedback. 8. Follow up of previous management review. 9. Changes that could affect the Quality Management System And 10. Weak areas and recommendations for improvement.

Steps for a typical quality assurance process:

There are many forms of QA processes, of varying scope and depth. The application of a particular process is often customized to the production process. A typical process may include: test of previous articles plan to improve design to include improvements and requirements manufacture with improvements review new item and improvements test of the new item

Company Quality:
During the 1980s, the concept of company quality with the focus on management and people came to the fore. It was realized that, if all departments approached quality with an open mind, success was possible if the management led the quality improvement process.

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The company-wide quality approach places an emphasis on four aspects:i. ii. iii. iv. Elements such as controls, job management, adequate processes, performance and integrity criteria and identification of records Competence such as knowledge, skills, experience, qualifications Soft elements, such as personnel integrity, confidence, organizational culture, motivation, team spirit and quality relationships. Infrastructure (as it enhances or limits functionality)

The quality of the outputs is at risk if any of these aspects is deficient. QA is not limited to the manufacturing, and can be applied to any business or nonbusiness activity:

Design work Administrative services Consulting Banking Insurance Computer software development Retailing Transportation Education

It comprises a quality improvement process, which is generic in the sense it can be applied to any of these activities and it establishes a behavior pattern, which supports the achievement of quality. This in turn is supported by quality management practices which can include a number of business systems and which are usually specific to the activities of the business unit concerned. In manufacturing and construction activities, these business practices can be equated to the models for quality assurance defined by the International Standards contained in the ISO 9000 series and the specified Specifications for quality systems. In the system of Company Quality, the work being carried out was shop floor inspection which did not reveal the major quality problems. This led to quality assurance or total quality control, which has come into being recently.

ISO 9000:
KS&EW has pioneered implementation of Quality Management System ISO 9000 in Pakistani industry. The decision of ministry of defense to build AGOSTA 90B submarine in Pakistan with the collaboration of French shipyard encouraged KS&EW management to obtain ISO 9000 International Quality Standard Certification for SWCD, which has now merged with Ship-Building (SB) division. After effective implementation of ISO 9000 Quality Management System in SWC Division which was certified in 1997, KS&EW Management decided to extend the coverage of ISO 9000 QMS scope to other division of KS&EW. Therefore the next divisions which qualified for ISO certification were GED (General Engineering Division) certified in 1999, SBD (Ship-Building Division) in 2000, and

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finally SRD (Ship-Repair Division) in February 2002. Now the ISO 9001:2008 certification for all above division has been renewed in November 2008.

Certification:
ISO does not itself certify organizations. Many countries have formed accreditation bodies to authorize certification bodies, which audit organizations applying for ISO 9001 compliance certification. Although commonly referred to as ISO 9000:2000 certifications, the actual standard to which an organization's quality management can be certified is ISO 9001:2008. Both the accreditation bodies and the certification bodies charge fees for their services. The various accreditation bodies have mutual agreements with each other to ensure that certificates issued by one of the Accredited Certification Bodies (CB) are accepted worldwide.

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Level I: Quality System Manual:

1. The Quality System Manual is a first level document outlining the Quality Policy, Quality Objectives and Structure & general principles of operation of Quality System. 2. The Quality System Manual shows how KS&EW intends to meet the requirements of ISO 9001:2000 and now the ISO 9001:2008 standards. 3. The Quality System Manual is a controlled document and is issued through Quality Assurance (QA) department to relevant departments/sections.

Level II: Quality System Procedures (system Element Procedures):

1. KS&EW has developed more detailed second level document i-e System Element Procedures. 2. The Quality Management System Procedures specify what has to be done, by whom, how and when will it be done with-in the scope of the Quality Management System. 3. All Quality Management System Procedures have a common format which includes purpose of the procedure, scope and the detailed step by step instruction in accordance with the ISO 9001:2008 standard. A list of all forms and appendices are included at the end of these procedures.

Level III: Work Instructions/ Process and Inspection Procedures:

1. KS&EW has developed more detailed third level documents. 2. The work instructions are detailed instructions, which are easily understandable and only address the task/work to be performed. 3. The work instructions are written for a specific task/inspection and testing methods/procedures, any special jobs, in order to simplify the operation of that particular task/work.

Level IV: Applicable Standards, Products Drawings, Technical Specifications, Forms, Check Sheets and Quality Records:
KS&EW has forth level documents to support Quality System Procedures and the Work Instruction.

Due to the high effectiveness of the ISO 9000, and ISO 9001:2000 Quality Management System, KS&EW Management has now achieved certification against ISO 9001:2008 version. This new version of KS&EW Quality Management System Manual has been prepared which outlined the Quality Management System in KS&EW based on Process Approach. ***** *****

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Ship Building Hall:

Ship-Building Hall (SBH) is the 1st important part of the ship building process. It is the place where construction of Ship-Building starts. Ship-Building is also known as Feeding Shop. This hall is divided into four sections, namely; 1. 2. 3. 4. CC-521 (Short Blast Section) CC-522 (Forging Shop) CC-523 (Marking Section) CC-524 (Cutting and Bending Section)

1. CC-521 (Short Blast Section):

This is also known as short blast plant. Drawings are issued from the design office through planning department. According to the drawings material is taken from the main store. The materials (i-e steel plates) are brought from the steel-yard situated at the corner of the SBH. Electromagnets or mobile cranes move the materials directly from one end to other, or materials are moved through conveyer belts. The materials are first moved to the short blast plant where steel plates (materials) are forcefully hit through mild steel balls, this remove and cleans all the contaminants (usually rust) from the metal plates. After short blasting worker coat the sheets with primer to protect it from decay. Plate Breath 1m3m Plate Thickness 4 mm 50 mm 2. 13 Roller Straightening Machine Up to 15 mm Straight 3. Johns Mobile Crane (02) Cranes 25 Ton Each 4. Over Head Crane (02) Cranes 10 Ton Each Machinery list of CC-521 1. Short Blast Plant

2. CC-522 (Forging Shop):

This portion is also known as forging shop. After sheets have been cleaned they are moved to the forging shop. In SBH both types of forging (i-e cold and hot forging) are done. According to the design the sheets are shaped. 1. Profile Bending Machine Capacity 500 Ton 2. Light Profile Bending Machine - - - -3. Face Plate - - - -Machinery list of CC-522

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3. CC-523 (Marking Section):

After all the work is done on metal sheets as required, then it is marked with number, size and other vital information, now the sheet part is ready and sent to the cutting and bending where the cutting and bending of these sheet are carried out as required.

4. CC-524 (Cutting and Bending Section):

This portion is also called cutting and bending shop. Here the sheets are cut and bent according to the issued drawings, and marking done in Marking Section in this section cutting usually done by gas cutting process known as oxy-cutting for which a mixture of oxygen, methane and acetylene is used. 1. Water Plasma Cutting Machine 2. CNC Cutting Machine (Oxy & Plasma) 3. Pieorex Oxy Cutting Machine 4. French Oxy Cutting Machine 5. Edge Planner Machine 6. Hydraulic Press Machine 7. Shearing Machine (See Picture)***** Sicomat Cutting Machine Scale # 1:10 Omnimat Cutting Machine Scale # 1:10 Optical Cutting Machine Scale # 1:1 (See Picture)***** To make the Bevel Capacity 850 Ton Capacity 300 Ton Cutting Capacity Up-to 10 mm

Water Plasma Cutting Machine

Optical Cutting Machine

CNC Cutting Machine

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Conclusion:
We have completed our Internship in the Karachi Shipyard and Engineering Works Limited.

During this short time we interned in the mention departments at KS&EW. Despite the short stay in each department, we learned a lot from each one of them.

In our short time, we observed that KS&EW is a well organized Industry, Each of its department is connected with each other by formally and working in very good coordination. Each kind of facility for production/Sheet body fabrication is available in KS&EW.

As for trainees, we dont think that any organization is better than KS&EW because each person from worker to management is too much trained and cooperative. We gain a lot of technical knowledge from KS&EW which we will never forget and also this will help us a lot in our professional life.

We are too much thankful to KS&EW employees, for great cooperation with us during our internship..

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