introduction to restructuring mid-tier shipyard by...
TRANSCRIPT
1 University of Rostock | Naval Architecture and Ocean Engineering February 2013 University of Rostock | Naval Architecture and Ocean Engineering
Introduction To Restructuring
Mid-Tier Shipyard By Developing Rough Layout Concept
Rafael Callamand
2 University of Rostock | Naval Architecture and Ocean Engineering February 2013
AGENDA
► Introduction
► Objectives
► Approach
► Theoretical Foundation
– Ship Production Processes
– Simulation in Shipbuilding Industry
– Description of Mid-tier shipyard
► Data Collection
► Experimental Procedure
► Conclusions
3 University of Rostock | Naval Architecture and Ocean Engineering February 2013
INTRODUCTION
► Shipyards facing the crisis
– Change in their strategies
► Optimization of shipbuilding processes
– Reducing delivery time/cost
► Simulation as tool for shipbuilding industry
– Simulation of very complex systems
4 University of Rostock | Naval Architecture and Ocean Engineering February 2013
OBJECTIVES
DES model for production process
Coarse layout method
Data requirement
what if scenarios
5 University of Rostock | Naval Architecture and Ocean Engineering February 2013
APPROACH
DES model for production process
DES simulation tool
Coarse layout method
Long –term capacity planning
Data requirement Information derived
from real project
what if scenarios
Assessment of new scenarios
6 University of Rostock | Naval Architecture and Ocean Engineering February 2013
THEORETICAL FOUNDATION
► Ship Production Process
– Product Work Breakdown Structure – PWBS
• Hull Block Construction Method – HBCM
• Zone Outfitting Method – ZOFM
• Zone Painting Method – ZPTM
• Pipe Piece Family Manufacturing (PPFM)
7 University of Rostock | Naval Architecture and Ocean Engineering February 2013
THEORETICAL FOUNDATION
► Simulation in Shipbuilding
– Monte Carlo Simulation
• Time unnecessary
– Continuous Simulation
• Mathematical models
– Discrete Event Simulation
• Event occur at an instant
8 University of Rostock | Naval Architecture and Ocean Engineering February 2013
THEORETICAL FOUNDATION
► Description of Mid-tier Shipyard
– Capacities
– Classification as mid-tier shipyard
http://desarrolloydefensa.blogspot.de/2008/08/cotecmar-excelencia-en-astilleros.html
9 University of Rostock | Naval Architecture and Ocean Engineering February 2013
DATA COLLECTION
► Product data
– Project’s information
► Production data
– Performance (m/h)
– Elements 1 ton-steel
► Structural data
– Schedule
10 University of Rostock | Naval Architecture and Ocean Engineering February 2013
EXPERIMENTAL PROCEDURE
► Simulation Tool Description
– Objects represented by icons
– Hierarchically structured
– Graphical representation
https://www.plm.automation.siemens.com/en_us/products/tecnomatix/plant_design/plant_simulation.shtml#lightview-close
11 University of Rostock | Naval Architecture and Ocean Engineering February 2013
EXPERIMENTAL PROCEDURE
► Current scenario
– Hull weight distribution
– Workflow
PLATESTORAGE180%
STORAGECUTTINGPLATES80%
PLATESTORAGE(HANGAR)
STORAGEPROFILES
WORKINGSPACEFLATPANELS
WORKINGSPACEFLATPANELS
CURVEPANELFORMATION37%
PRE-ASSEMBLY
BLOCK-ASSEMBLYSTERN(14%)
MID(78%)BOW(8%)
RINGASSEMBLY100%
HULLERECTION&PAINTINGZONE
100%
2DBENDINGPLATEMACHINE
PRE-ASSEMBLY
CUTTINGPLATEM
BENDINGPROFILESM
STORAGEPROFILES
WORKSHOP1
WORKSHOP2
WORKSHOP3
7%
20% 80%
7%
7%
30%
50%
31,5%
31,5% 25%
25%
6,5
%
12 University of Rostock | Naval Architecture and Ocean Engineering February 2013
EXPERIMENTAL PROCEDURE
► Current scenario
– Unidirectional workflow
– Stations
13 University of Rostock | Naval Architecture and Ocean Engineering February 2013
EXPERIMENTAL PROCEDURE
► Scenario 1. Welding Robot in the production line
http://cfnewsads.thomasnet.com/images/large/515/515802.jpg
14 University of Rostock | Naval Architecture and Ocean Engineering February 2013
EXPERIMENTAL PROCEDURE
► Scenario 2. Restructuration of the Current Layout
Current Layout Restructured Layout
15 University of Rostock | Naval Architecture and Ocean Engineering February 2013
EXPERIMENTAL PROCEDURE
STATION CURRENT SCENARIO Welding Robot Scenario Restructuration of the current layout
Processing Time Set-up Time Processing Time Set-up Time Processing Time Set-up Time
Warehouse 2h:30m 2h:30m 2h:30m
Plate Storage 1h:00m --- 1h:00m --- 1h:00m ---
Profile Storage 1h:00m --- 1h:00m --- 1h:00m ---
Cutting Machine 1h30m 00h:45m 1h30m 00h:45m 1h30m 00h:30m
Bending Workshop 7h:00m 2h:00m 7h:00m 2h:00m 7h:00m 00h:45m
Flat pre-assembly workshop 3h:30m 1h:30m 1h:30m 1h:30m 3h:30m 00h:45m
Flat assembly workshop 3h:30m 2h:00m 3h:30m 2h:00m 3h:30m 3h:30m
Curve pre-assembly workshop 6h:00m 2h:00m 6h:00m 2h:00m 6h:00m 6h:00m
Curve assembly workshop 6h:00m 2h:00m 6h:00m 2h:00m 6h:00m 6h:00m
Aft-bow assembly blocks ws 4h:00m 1h:30m 4h:00m 1h:30m 4h:00m 4h:00m
mid-ship assembly blocks ws 3h:00m 1h:30m 3h:00m 1h:30m 3h:00m 3h:00m
16 University of Rostock | Naval Architecture and Ocean Engineering February 2013
EXPERIMENTAL RESULTS
100%
95%
107%
97%
Real Process Current Scenario Welding Robot Scenario Change Layout Scenario
17 University of Rostock | Naval Architecture and Ocean Engineering February 2013
EXPERIMENTAL RESULTS
STATION CURRENT SCENARIO Welding Robot Scenario Restructuration of the current layout
Processing Time Set-up Time Processing Time Set-up Time Processing Time Set-up Time
Warehouse --- 2h:30m 2h:30m --- 2h:30m
Plate Storage 1h:00m --- 1h:00m --- 1h:00m ---
Profile Storage 1h:00m --- 1h:00m --- 1h:00m ---
Cutting Machine 1h30m 00h:45m 1h30m 00h:45m 1h30m 00h:30m
Bending Workshop 7h:00m 2h:00m 7h:00m 2h:00m 7h:00m 00h:45m
Flat pre-assembly workshop 3h:30m 1h:30m 1h:30m 1h:30m 3h:30m 00h:45m
Flat assembly workshop 3h:30m 2h:00m 3h:30m 2h:00m 3h:30m 2h:00m
Curve pre-assembly workshop 6h:00m 2h:00m 6h:00m 2h:00m 6h:00m 2h:00m
Curve assembly workshop 6h:00m 2h:00m 6h:00m 2h:00m 6h:00m 2h:00m
Aft-bow assembly blocks ws 4h:00m 1h:30m 4h:00m 1h:30m 4h:00m 1h:30m
mid-ship assembly blocks ws 3h:00m 1h:30m 3h:00m 1h:30m 3h:00m 1h:30m
THROUGHPUT 474 tons 532 tons 483 tons
18 University of Rostock | Naval Architecture and Ocean Engineering February 2013
RECOMMENDATIONS
► Develop very fine simulation model
► Evaluate impact of new machinery before investment
► Include all the processes related with shipbuilding
19 University of Rostock | Naval Architecture and Ocean Engineering February 2013
CONCLUSIONS
DES model for production
process
DES simulation
tool
DES tool shown
capabilities
Coarse layout
method
Long –term capacity planning
Rough layout concept as useful tool
Data requirement
Information derived from real project
Analysis of the information gathered
what if scenarios
Assessment of new scenarios
Evaluation of current and two new scenarios