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Transcript of Shipyard 4.0: The Ferrol Navantia Shipyard Model for ... · Shipyard 4.0: The Ferrol Navantia...
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Shipyard 4.0: The Ferrol Navantia Shipyard Model
for Planning in Shipbuilding
Alejandro García del Valle – Head Modelling and Simulation: Joint Research Unit Navantia-UDCMarcos Rouco Couzo, Mar Cebral Fernández, Marta Quiroga Pazos
Integrated Group for Engineering ResearchUniversidade da Coruña, Spain
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1. Introduction
2. Simulation Model
3. Experimentation and Results
4. Conclusions
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1. Introduction
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Introduction
High international competitiveness
• Shortest delivery term• Lower cost• High level of quality
Need to manufacture
Complexity of shipbuilding process
• Unique (not serialized)• High added value• Long construction period
Diversity and # of elements
Product (Frigate)
Non lineal process • Complex coordination between stages / workshops
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2. Simulation Model
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Model development
Frigate 25 Blocks 50 Sub-blocks
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Input Data Simulation Model Results
- Developed in ExtendSim- Easy integration with SAP
- Excel interface for input data- Connected with Extendsim
- Results tables- Gantt Chats
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Model development
• 5 sub-blocks typology
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Main sub-blocks attributesTypology # Web frames # Beams
Weight # Longitudinal girders # Spare parts (webs)
# Straight panels # Transverse girders # Profiles (webs)
# Shell panels # Double bottom girders # Spare parts (panels)
# Longitudinal profiles # Bulkheads # Profiles (panels)
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Model development
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• Input sequence • Disaggregation process
Main data analyzed
Sheets cutting lengths
Welding lengths
Sheets thicknesses
Transport lot sizes
Profiles dimensions
Sheets dimensions
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Model development
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Simulation process
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ERP (SAP)
Excel (Model data)Blocks and subblocks data
Excel VBA Macro• Ratios• Resource capacity
ExtendsimSimulation Model
First phase:• General scheduling• Gantt Chart
Second phase:• Detailed scheduling• Specific analysis by workshop
Data input Simulation Results
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Model & Hierarchical blocks
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4. Experimentation and Results
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Experimentation and resultsExp. 1 – Improved production scheduling
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• Aggregate planning at early stages of the project
• Objective: to find an improved production scheduling.
• From first stage: first workshop
• To last stage: arrival at the slipway
• Considerations:
• Blocks assembly sequence in the slipway is fixed and predefined
• Hard planning work
• Big differences between blocks in dimensions, shape, structural conditions, etc.
• Non linear process
• Early stages of the project, when detailed technical data are unavailable
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Experimentation and resultsExp. 1 – Improved production scheduling
Real ship scheduling
Improved ship scheduling
• 30% makespan reduction.
• Balanced resources.
• Buffers reduced
• Long manufacturing times
• Unbalanced resources.
• Long waiting times.
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Experimentation and resultsExp. 1 – Improved production scheduling
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Real ship sequence Improved ship sequence
Available bays in Subassembly workshop.
• Less balanced utilization rate • More balanced utilization rate
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Experimentation and resultsExp. 1 – Improved production scheduling
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Real ship sequence Improved ship sequence
Buffer of blocks waiting for painting process
• 12 blocks in buffer
• Long waiting times
• 6 blocks in buffer
• Short waiting times
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Experimentation and resultsExp. 2 – Analysis of the Cutting & Welding workshop
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• Very important: 1st stage of the process
• All other stages need that all parts arrive as soon as possible
Cutting
Cutting
Cutting
OSW PTU MGB SMWP SSMP VRWP
SSMP VRWP
Profiles
Panels
Webs Web line
Panel line
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Experimentation and resultsExp. 2 – Analysis of the Cutting & Welding workshop
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• Level: detailed.
• Objective: Analyze the workshop to detect the limiting resources and select the most
appropriate actions to improve its utilization rate and thus reduce the workshop's makespan.
• Results:
• The welding station (VRWP) of the web line is the bottleneck of the workshop.
• Utilization rate mounting station (SSMP): 29%
• Utilization rate welding station: 97.2%
• Actions:
• Increase of the capacity of the welding station in the web line would increase the overall
capacity of the workshop, reducing the makespan of this workshop by 50%.
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Experimentation and resultsExp. 3 – Panel line: maximum capacity analysis
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Cutting
Cutting
Cutting
OSW PTU MGB SMWP SSMP VRWP
SSMP VRWP
Profiles
Panels
Webs Web line
Panel line
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Experimentation and resultsExp. 3 – Panel line: maximum capacity analysis
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• Level: detailed.
• Objective: Determine the maximum capacity of the panel line (Cutting & Welding workshop).
• Experiment:
• The line is saturated, generating all part and components of 2 frigates at start time.
• Different scenarios are generated, changing the number of Mounting and Welding
stations and the shifts number.
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Experimentation and resultsExp. 3 – Panel line: maximum capacity analysis
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• Results: The best scenario is the one with 2 Mounting and 2 Welding stations.
• # shifts: depend on the capacity needed to meet the milestones agreed with the client
and the associated costs.
Shifts Mounting stations
Weldingstations
Maximum capacity (95% CI)(panels/week)
Maximum capacity (95% CI)(blocks/week)
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1 1 2.598 ± 0.015 0.411 ± 0.002
1 2 2.756 ± 0.014 0.436 ± 0.002
2 2 4.646 ± 0.042 0.735 ± 0.007
2 4 4.759 ± 0.042 0.753 ± 0.007
2 1 3.686 ± 0.026 0.583 ± 0.004
2
1 1 5.138 ± 0.060 0.813 ± 0.010
1 2 5.487 ± 0.044 0.868 ± 0.007
2 2 9.340 ± 0.110 1.478 ± 0.017
2 4 9.550 ± 0.066 1.511 ± 0.010
2 1 7.365 ± 0.053 1.165 ± 0.008
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5. Conclusions and Future Research
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Conclusions (a)
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• A multilevel simulation model for a shipyard has been proposed and validated.
• Two level: aggregate (first stage of the project) and detailed (when project has started).
• Software used: Extendsim. Right now: is a 3D model using Flexsim.
• 3 experiments
• Experiment 1: aggregate level. Useful at the beginning when little information in available.
The modeled obtains an “improved scheduling” reducing the makespan by 30% with a
balanced use of resources.
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Conclusions (b)
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• Experiments 2 and 3: detailed level. Aiming at a detailed analysis of first workshop of the
shipyard: the Cutting and Welding workshop.
• Experiment 2 allows to characterize the bottlenecks and how the capacity of this workshop
affects the makespan.
• Experiment 3 allows to determine the maximum capacity of the panel line (Cutting & Welding
workshop) and find the best alternative to fulfill the milestones of the client.
• The model will be implemented in the Navantia military shipyard (Ferrol, Spain).
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Conclusions (c)
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• Probably: the first complete virtual shipyard with all its workshops.
• The model allows to check many scenarios and all “building strategies”.
• The model will be implemented in the Navantia military shipyard (Ferrol, Spain).
• Many results has already been implemented.
• This virtual shipyard is a competitive advantage of Navantia for doing business with its clients.
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Future Research
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• Develop scheduling heuristics in order to get an “optimized” schedule that minimizes the total
makespan.
• Get detailed 3D models of each of the workshops of the shipyard.
• Optimize the shipyard layout using simulation.
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Thanks for your attention
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Integrated Group for Engineering Research
www.gii.udc.es