August 2013

Content

1.
2.
3.
4.
5.

General Overview
Quality and HSE Management System
DMHIs ERP System
Facilities and Capacities
Performance Record

1. General Overview

Location

E87

E87

Mangalia
Harbor

History
DMHI,-Most Competitive
Heavy Industry in Europe
Daewoo Brand

2 Mai Mangalia
Shipyard
Joint Venture

1997
1974

INTEGRATION

2008

EARLY
STAGE

1974-1978 Construction of
shipyards site, Dry Dock No. 1 & 2
1976-1997 Construction of various
newbuilding projects such as
Bulkcarrier 65,000 TDW / 100,000
TDW, Crude Oil Tankers of 89,000
TDW, as well as Offshore Jackets and
the hull of the Frigate Marasesti
1985 Start operating the 3rd and
largest dry dock used for shiprepair
business

Jan. 22 1997 Daewoo-Mangalia Heavy

Industries S.A. is founded as a joint venture
company between Daewoo Shipbuilding &
Marine Engineering Co.,Ltd.(Korea) and 2
Mai Mangalia Shipyard S.A.(Romania)

MODERNIZATION
INNOVATION

Present

2008~2009 Expansion of the shipyard site for

new assembly and painting facilities and
conversion of Dry Dock No.3 for newbuilding
activity
2009 Delivery of the biggest vessels ever
built in Black Sea and Mediterranean Sea area :
> 5,905 TEU for Hamburg Sud/Germany
> 180K Capesize B/C for Tsakos / Greece

2004 DMHI shifts its newbuilding strategy

on the construction of complete big size
commercial vessels only
(Panamax / Post- Panamax Containerships,
Panamax Tankers, Capesize BC)

2011 Setting a record in number of vessels

delivered: 11 vessels, of which 5
Containerships, 3 Bulk Carriers, 2 AHTs and 1
submersible drilling barge

End 2007 DMHI stops its ship repair

business activity in order to construct only
large-size new buildings

2013 Delivery of 8,600 TEU Containership for

Zodiac Maritime, which is the next biggest
vessel ever built in the Black Sea and
Mediterranean Sea area

Shareholder Structure

ROMANIAN
GOVERNMENT
2 Mai Mangalia
Shipyard
49%
FACILITY (US$ 50.9 mil)

DSME (Korea)
Daewoo Shipbuilding
& Marine Engineering
51%
CASH (US$ 53.0 mil)
and
KNOW-HOW

Organization Chart of DMHI

BOARD OF DIRECTORS
PRESIDENT & CEO
CORPORATE
INNOVATION OFFICE

VICE PRESIDENT
HSE
OFFICE

MANAGEMENT UNIT

PRODUCTION UNIT

PRODUCTION SUPPORT UNIT

MANAGEMENT PLANNING
DIVISION

PRODUCTION CONTROL
DIVISION

DESIGN
DIVISION

MARKETING & CONTRACT

MANAGEMENT DIVISION

INDOOR
DIVISION

QUALITY MANAGEMENT
DIVISION

HUMAN RESOURCES MANAGEMENT

& GENERAL AFFAIRS DIVISION

PREOUTFITTING
DIVISION

MAINTENANCE & UTILITY

DIVISION

MATERIALS
DIVISION

OUTDOOR HULL
DIVISION

PRODUCTION STRATEGY &

PLANNING TEAM

OUTDOOR OUTFITTING
DIVISION

Organization & People

SUBSIDIARIES
752 employees

PRODUCTION
(Workers and Foremen)
1,882 employees

INTERNAL
SUBCONTRACTORS
2,944 employees

As of 1 August 2013

DMHI
Subsidiaries

2,525 employees
752 employees

Subcontractors

2,944 employees

TOTAL

6,221 employees

Business Concept

An industry leader in the global shipbuilding

and offshore market.
Most advanced competitive edge
shipbuilding and offshore.

Continuous know how transfer

Client satisfaction

Vessel with high quality & technology

DESIGN

DSME Marketing
Engineering
Tendering &
Concept Design

SUPPLY CHAIN

DSME / DSEC Supply

for Main Equipment
(Mainly Korea & Far East)

PRODUCTION

DSME / DSEC(*)
Detail Engineering
(Class Approved
Drawing)

DSME Initial
& Basic Design
(R&D, Model Test)

DMHI Purchase
Bulk Material
(Plate / Profile / Paint)

DSME
Know-How
Method / Machine

DMHI
Production
Design

DMHI Production
Engineering Support

DMHI Storage and

Inventory Management
(through ERP System)

DMHI Production
Planning
(through ERP System)

DMHI
Entirely In House
Production

DMHI
HSE Strong Policy

DMHI Quality
Control at DSME
Standard

(*) DSEC: DSME subsidiary for engineering and procurement

2. Quality and HSE Management System

10

Integrated Management System (IMS) - Certification: December 2010

Implementing the Integrated Management System for Quality, Environmental and

Occupational Health & Safety, designed and documented in accordance with requirements of
ISO 9001:2008

ISO 14001:2008

11

OHSAS 18001:2007

HSE Management Policy

Safety First
Health & Safety
Policy

Health & Safety

Regulation

Health & Safety of all

employees is the most
important point in every
step of operations

Rewards

Zero accident record

Remarkable suggestion
Remarkable contribution
Services as deemed to be

Health & Safety regulation

is applicable to all
employees, all
subcontractors and visitors

Customer
Satisfaction
And
Recognition

12

Punishments
Disrespect to the
instruction
Absentee on HSE education
Violation of safety rules
Default, protection device
wearing

HSE Indicators

Indicator

2008

2009

2010

2011

2012

TRIR

1,20

0,91

1,15

0,95

0,74

DART

1,35

1,21

0,98

0,86

0,55

LTIR

0,24

0,30

0,44

0,45

0,23

Pollutions

Total Recordable Incident Rate (TRIR)= (no. of Total Recordable Case) x 200,000
Total Working Hours
Days Away, Restricted or Transferred (DART) = (no. of Days Away Case+ no. of Restricted Case) x 200,000
Total Working Hours
Lost Time Incident Rate (LTIR) = (no. of Lost Time Incident) x 200,000
Total Working Hours
Pollutions no. of pollutions

13

3. DMHIs ERP System

14

DMHIs ERP System - MAGICS

MAGICS

Material Management System

Production Management System

Production Planning System

Basic Information

PML

Basic Information

Work Order Control

Basic Information

Middle Term Schedule

Hull BOM

Material Delivery

Production Design

Logistics

Long Term Schedule

Short Term Schedule

Outfitting BOM

Material Arrival

Production Plan

Production Analysis

PO Request

Inventory/Closing

Subcontractor Work Control

Purchase Order

Owner Supply Item

Block Control

Quality Management System

Human Resource Management

Basic Human Mgmt

Salary Calculation

Job Evaluation

Training & Education

Design Management System

Basic Information

Inspection Plan

Basic Information

Drawing Plan

Inspection Request

Inspection Schedule

Drawing Results

Drawing Analysis

Inspection Results

Quality Problem

Document Control

Quality Analysis

[ MAGICS Login Screen ]

15

DMHIs ERP System System Connectivity

Production Planning
System

Production Planning
System

- Long & Middle Term-

- Short Term -

Design Management
System

Logistics
(Steel Mat./Outfit.Fab./Block/Pieces)

Production Management System

Material Management
System

Quality Management
System

16

Human Resource
Management

Financing
&
Accounting

DMS (Design Management System)

MAGICS system DMS module is an integrated informational system that provides data related
to drawing planning, drawing revision status, Design M/H consumption.

* DMHI controls drawing planning, drawing issuing status, drawing revision status, design
M/H consumption through MAGICS.
17

DMS (Design Management System)

Scanned drawings
can be printed
18

MMS (Material Management System)

MMS module is an integrated informational system that provides data related to material POR, PO
as well as stock management and delivery of the items to the production.

19

PMS (Production Management System)

Sample Production Progress for Hull No. 4091 (PMS Data)

20

QMS (Quality Management System)

21

QMS (Quality Management System)

22

4. Facilities and Capacities

23

DMHIs Production Facilities

Docks

YARD ENVIRONMENTAL DATA

Water Depth
Wave Height
Tide
Current
Ground Elevation
Median annual temperature
Thermal amplitude
Climatic type

:
:
:
:
:
:
:
:

No. 1

8 ~ 11 m
0.2 m
Null
Null
3 m above MSL (quay)
12.4 C
2325 C
Moderate Dry

Length

Width

Depth

302M

48M

9M

Cranes
G 2 x 480T
J 2 x 120T

Dry
Docks

No. 2

320M

48M

18M

J 1 x 50T
J 2 x 16T

No. 3

360M

60M

13M

G 1 x 1,000T
J 2 x 50T
J 2 x 16T

ANNUAL PRODUCTION CAPACITY

Production capacity
:
12 Vessels / year,
in equivalent of 12 vessels/year of 180,000 DWT bulk carriers and /
or 11,000 TEU containerships.

24

Site Area

980,000 m2

Outfitting Quay
Covered Shop
Storage Area
Steel Stock

:
:
:
:

Steel Cutting
Pre-Erection Platform

:
:

1,590 m
95,960 m2
6,500 m2 (Covered)
13,800 m2
35,000 Ton
15,000 Ton/month
20,000 m2

Shipyard Layout & Natural Environments

1. SSY - Steel Stock Yard

2. TLS - Treatment Line Shop
3. CAS Cutting & Assembly Shop
4. CSS Component & Sub-assy Shop
5. OHS Outfitting & Hull Shop
6. EAS Engine Assy Shop
7. CMS Comp. Fabr. & Maintenance shop
8. BTC Blasting Cells (Old)
9. PTC Painting Cells (Old)
10. BPC New Blasting & Painting Cells
11. SBC Steel Outfitting Blasting Cells
12. UGS Unit Module & Galanization Shop
13. APS Accommodation Preoutfitting Shop
14. HCS Hatch Cover Grand Ass'y Shop
15. MES M/E Storage Shop
16. PBS New Panel Block Shop
17. NGA New Grand Assy Platform
18. QAP Quay A Platform
19. QBP - Quay B Platform
20. QCP - Quay C Platform
21. PEP Pre-erection Platform
22. 1DK No.1 Dry Dock
23. 2DK No.2 Dry Dock
24. 3DK No.3 Dry Dock

25

Facilities for Hull Fabrication

Activity/Layout Code

Facilities

Concept / Remarks

Capacity (Area, Bays):

Cranes:

~35,000 ton (~16,100 m2, 6 )

8 x 20 ton mag. O/H

Korea, Ukraine, Romania

Treatment Line Shop

(TLS)

Capacity (Lane):
Max. Breadth & Length:

~30,000 ton / month, (2 Lanes)

4.2 m, 15 m

Modern facilities with blasting

system, dry oven and marking

Cutting
(CAS/CSS/PBS)

Plasma (Dry & Wet) :

Oxy-Gas:
Oxy-Gas Parallel Cutting:

~15,000 ton / month

4.2 m
15 m

Marshalling systematization
(DSME know-how);
Automatic beveling

Equipments:

2,000 ton roll bending

1,000 ton press
Profile bending

Maximum length of plate in

case of 2,000 ton roll bending:
13 m

Area:
Automatic T-Bar Line:

1,836 m2
Edge preparation
Automatic Weld, Straightening

The facility has two N/C OxyGas cutting machines.

Feeding Roller conveyor

Indoor:
Outdoor:
Cranes:

3,504 m2 , 3 bays
2,880 m2, 2 bays
2 x 50 ton, 2 x 5 ton, 1 x 3.2 ton

Complete fabrication process

inside of the shipyard

Steel Stock Yard

(SSY)

Bending
(CAS)
T-Bar Fabrication
(CMS)
Hatch Cover
Fabrication
(OHS / HCS)

26

Facilities for Outfitting Fabrication

Activity/Layout Code

Facilities

Concept / Remarks

Pipe Fabrication
(OHS)

Bays:
Bending M/C:
Pipe Rotators:

3
5
10

Inside fabrication ratio: ~ 90%

Facilities based on JIS Standard
TIG 300, Semi-auto Arc CO2

Steel Outfitting
Fabrication (OHS)

Bays:
Blasting & Painting:

2
Separate shops inside shipyard

Inside shipyard fabrication

ratio: ~ 80%

Galvanizing
(UGS)

Area (bays):
Treatment Baths:
Galvanizing Baths:

1,000 m2, (1)

9
7.5 m x 1.5 m x 1.7 m (435~450C)

Automatic control of
temperature and
environmental friendly

27

Facilities for Indoor Assembly

Activity/Layout Code
Minor Assembly
(CAS/CSS/PBS)

Facilities

Concept / Remarks

Cutting & Assembly (CAS):

Components & Sub-Assy (CSS):
Panel and Block (PBS) :

2 (296 m x 36 m x 25 m)
1 (296 m x 36 m x 14 m)
6 (60 m x 24 m x 10 m)

Largest 167 m x 45 m x 39.8 m

Panel Lines
(CAS/PBS)

Cutting & Assembly (CAS):

Panel and Block Shop (PBS):

2 (296 m x 36 m x 25 m)
1 (296 m x 36 m x 14 m)
1 (300 m x 32 m x 36.3 m)

PBS Semi-automatic line

Curved Assembly
(CAS/NGA)

Cutting & Assembly (CAS):

New Grand Assembly (NGA):
Gantry Cranes:

1 (296 m x 36 m x 25 m)
1 (296 m x 36 m x 14 m)
1 x 250 ton / 4 x 30 ton

Largest 270 m x 22.5 m

Submerged Arc Welding with
metallic powder (FGB)

Grand Assembly
(NGA/PBS)

NGA Platform and Cranes:

PBS Panel Line Output:

1 x 250 ton / 4 x 30 ton

600 ton Block Transfer Car
O/H Crane: 250 ton

PBS: Automated panel line

Max. block size: 30 m x 30 m

28

Facilities for Indoor Pre-outfitting

Activity/Layout Code

Facilities

Concept / Remarks

Area:
Cranes:

1,000 m2, 1 bay

2 x 10 ton O/H

Maximize the productivity of

pre-outfitting through preassembly of: supports, pipes,
equipment, electrical etc.

General
Pre-outfitting Shop

North Platform Bays:

Cranes:
NGA Bays:
Welding:
Tools:

4 (largest: 22m x 20m x 12m)

4 x 2.0 ton (1 for each bay)
3 (largest: 25m x 25m x 16.5m)
Semiautomatic CO2
Specialized related Pipe, Steel
Outfitting, Electrical Pneumatic
impact wrench, etc.

Pre-outfitting ratio: 85 - 90%

Similar with Top Korean
Shipyard

Accommodation
Pre-Outfitting (APS)

Dimensions:
Cranes:

34 m x 18 m x 10 m, 2 bays
1 x 3.2 ton O/H

Pre-outfitting ratio: 80 85%

Unit Module
Fabrication
(UGS)

29

Facilities for Indoor Blasting and Painting

Activity/Layout Code
Block Blasting Cells
(BTC)

Facilities

Concept / Remarks

No. of Cells:
Blasting Nozzles:

2 (30m x 22m x 15m)

16 sets

Steel shot blasting

Block Painting
Cells / Shelters (PTC)

No. of Cells:
Painting Shop:
Shelter:

1 (36m x 22m x 15m)

1 (97m x 22m x 13.5m)
1 (40m x 22m x 10m)

Steel shot blasting

New Block
Blasting Cells (BPC)

No. of Cells:
Blasting Nozzles:

2 (32.5mx31mx18.5m)
12 sets

Steel shot blasting

Environmentally friendly

New Block
Painting Cells (BPC)

No. of Cells:

2 (32.5mx31mx18.5m )

Environmentally friendly

Steel Outfitting
Blasting Cells (SBC)

No. of Cells:

2 (18.4m x 17.6m x 9m)

Steel shot blasting

Environmentally friendly

30

Facilities for Pre-erection & Outfitting

Activity/Layout Code

Facilities

Concept / Remarks

Pre-erection Platform
For Dock no. 1 & 2
(PEP/1DK/2DK)

Area:
Cranes (Working in Tandem):
Jib Cranes:

20,000 m2
2 x 480 ton (850 ton)
2 x 120 ton, 2 x 50 ton, 2 x 15 ton

Pre-erection welding joint

paint remedy is performed
before erection in Dry Dock

Pre-erection Platform
For Dock no.3
(3DK)

Total Area:
Goliath Crane:
Jib Cranes:

16,800 m2
1 x 1,000 ton
2 x 50 ton, 2 x 15 ton

Pre-erection welding joint

paint remedy is performed
before erection in Dry Dock

Heavy Transporters:

1 x 500 ton
2 x 450 ton
1 x 330 ton
1 x 138 ton

450 ton units - possibility to

work in tandem:
Maximum capacity 800 ton
Maximum load dimension:
52m x 22m x 15m

Transportation

31

Facilities for Erection in Dock Stage

Activity/Layout Code

Facilities

Concept / Remarks

Dry Dock no.1

(1DK)

Dimensions (Water Draft):

Gantry Cranes (Tandem):
Jib Cranes:
Utilities:

302m x 48m x 9m (7.35m)

2 x 480 ton (850 ton)
2 x 120 ton, 2 x 50 ton, 2 x 15 ton
Electric power, CO2, O2, LPG,
Compressed Air

Above Sea level with 9 m, in

line with Dry Dock no. 2
Launching of Dock no. 1 shall
be related with Dock no. 2
launching/partial launching

Dry Dock no.2

(2DK)

Dimensions (Water Draft):

Gantry Cranes (Tandem):
Jib Cranes:
Utilities:

318m x 48m x 18m (7.35m)

2 x 480 ton (850 ton)
2 x 120 ton, 2 x 50 ton, 2 x 15 ton
Electric Power, CO2, O2, LPG,
Compressed Air

Sea Level, aligned with Dry

Dock no.1

Dry Dock no.3

(3DK)

Dimensions (Water Draft):

Gantry Cranes:
Jib Cranes:
Utilities:

360m x 60m x 13m (8.5m)

1 x 1,000 ton
2 x 50 ton, 2 x 15 ton
Electric Power, CO2, O2, LPG,
Compressed Air

Sea Level

32

Facilities for Outdoor Outfitting in Quay Stage

Activity/Layout Code

Facilities

Quay A
(QAP)

Length (Platform Area):

Jib Cranes:
Bearing Capacity:
Utilities:

620m (620m x 20m)

1 x 50 ton, 1 x 15 ton
100 ton / m2
Electric Power, CO2, O2, LPG,
Compressed Air

Quay B
(QBP)

Length (Platform Area):

Jib Cranes:
Bearing Capacity:
Utilities:

430m (430m x 20m)

1 x 120 ton, 1 x 15 ton
200 ton / m2
Electric Power, CO2, O2, LPG,
Compressed Air

Quay C
(QCP)

Length (Platform Area):

Jib Cranes:
Bearing Capacity:
Utilities:

540m (540m x 10m)

2 x 50 ton
200 ton / m2
Electric Power, CO2, O2, LPG,
Compressed Air

33

Concept / Remarks

5. Performance Record

34

Performance Record (After Joint Venture)

Bulk Carriers:

Commercial
Vessels

Tankers:

Capesize: 7
Kamsarmax: 6
Handysize: 13
Coaster: 30
Coaster Combi
Freighter: 6

Crude Oil Tanker: 3

Chemical: 5
Handymax Juice
Carrier: 2

Containerships:
Post Panamax: 13
Panamax: 10
Feeder: 43

Total: 138
Floating Docks

Offshore and Offshore

Support Vessels

Total: 3
AHT: 2

Drilling Rig Barge: 1

Total: 6
Barges: 5

Barges

PSV: 3

Pontoon Barges: 46

Total: 51
35

DMHIs New Building Performance Record

69,000 TDW Crude Oil Tanker

LxBxDxd
228.0 x 32.2 x 19.8 x 12.2 (m)
Class
American Bureau of Shipping
Units built
3 (HNs. 5003 / 04 / 05)
Buyer / Actual Owner LMZ Greece / ELETSON Corporation - Greece

36

DMHIs New Building Performance Record

4,860 TEU Containership

LxBxDxd
Class
Units built

Buyer

275.0 x 32.2 x 21.5 x 12.0 (m)

Germanischer Lloyd
4 (HNs. 4052 / 53 / 54 / 55)
4 (HNs. 4062 / 63 / 64 / 65)
2 (HNs. 4073 / 75)
NSB GEBAB CONTI / Germany
37

DMHIs New Building Performance Record

5,560 TEU Containership Monte Class

LxBxDxd
Class
Units built
Buyer
38

272.0 x 40.0 x 24.2 x 12.5 (m)

Germanischer Lloyd
3 (HNs. 4066 / 67 / 68)
Hamburg Sd / Germany

DMHIs New Building Performance Record

5,905 TEU Containership Rio Class
LxBxDxd
Class
Units built
Buyer

286.45 x 40.0 x 24.2 x 12.5 (m)

Germanischer Lloyd
3 (HNs. 4069 / 70 / 71)
Hamburg Sd / Germany

39

DMHIs New Building Performance Record

180,000 TDW Bulkcarrier

LxBxDxd
Class
Units built
Buyer

292.0 x 45.0 x 24.7 x 16.5 (m)

BV (3 units) / DNV (1 unit) / LRS (1 unit) / GL (2 unit)
7 (HNs 1045 / 46 / 47 / 48 / 50 / 51 / 52)
Tsakos (2 units) / Greece
Anangel Maritime Services (3 units) / Greece
Claus Peter Offen (2 units) / Germany
40

DMHIs New Building Performance Record

5,550 TEU Containership

LxBxDxd
Class
Units built
Buyer
41

270.4 x 40.0 x 21.7 x 12 (m)

Germanischer Lloyd
6 (HNs 4082 / 83 / 84 / 85 / 86 / 87)
Claus Peter Offen / Germany

DMHIs New Building Performance Record

100 TBP Anchor Handling Tugboat
LxBxDxd
Class
Units built
Buyer

48.87 x 13.8 x 7 x 5.2 (m)

Lloyds Register
2 (HNs 6003/6004)
AHT Commander / Germany

42

DMHIs New Building Performance Record

82,000 TDW Bulkcarrier
LxBxDxd
Class
Units built
Buyer

229.0 x 32.26 x 20.2 x 12.2 (m)

3 Bureau Veritas / 1 NKK / 2 LR
6 (HN 1053/54/55/56/57/58)
Larus (2 units) / Greece
Dalnave (2 units) / Greece
KC Maritime (2 units) / Hong Kong

43

DMHIs New Building Performance Record

8,600 TEU Containership

44

DMHIs Orderbook
TYPE

CAPACITY

NUMBER

OWNER

COUNTRY

Containership

8,600 TEU

Zodiac

UK

Pure Car
Truck Carrier

6,500 Units

Ocean Yield AS

Norway

Product Carrier

112,000
TDW

Eastern Mediterranean
Maritime

Greece

Containership

9,100 TEU

Capital Ship

Greece

Hull for Multipurpose Subsea

Construction Vessel

Bergen Group
BMV AS

Norway

Hull for Multipurpose Subsea

Construction Vessel

Bergen Group
Fosen AS

45

Norway

DAEWOO-MANGALIA
HEAVY INDUSTRIES
46