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Lessons Learned from the Shipbuilding Industry

Rob Glasier, AVEVA Doug Martin, NASSCO Dr. Richard Storch, University of Washington

Why Shipbuilding?

Why Shipbuilding?

Many Parallels to our industry – Design Technologies similar – Large Capital Projects – Most components, systems, materials, the same or similar – Many engineering companies are in all sectors

Shipbuilding borrows a lot from Automotive/Aerospace – Cross-over technologies between industries – Adopted technology from other sectors might be applicable to Process/Power – Beginning to look at a ship more like a large “Product”, rather than a large “Project”

Some Differences Shipbuilding

Rest of Industry

Fixed production location

Site built

Single ownership of design and production assets

Fragmented ownership

Established design rules

Custom designs

Fixed production approach and sequence

Determined by project

But, overall the parallels outweigh the differences And, most of the differences can be adapted to the “Product” approach

Evolution of Shipbuilding Construction method

Shipbuilding

Process/Power

Stick Building

Over the past two decades, Japanese and Block South BuildingKorean

shipbuilders have embraced

product orientation Product Oriented

Commercial Shipbuilding Traditional vs. Product Oriented

Cost performance ﾂザ.S.: $150 million ﾂカapan: $33 million

4.5 times Source: Holcomb 2002

Commercial Shipbuilding Traditional vs. Product Oriented

Schedule performance ﾂザ.S.: 36 months ﾂカapan: 6 to 9 months

4 to 6 times

Source: Holcomb 2002

What is Driving This Interest ?

Productivity step-change is needed in the rest of the industry – – – –

Labor shortages Energy needs Material availability Project lead times

Competitive edge – all the way to the end-user – the Owner/Operator

Floating, Movable Cities

Global Shipbuilding Industry Percentage of Total Value of Ship Market All Others 10% European Union 11% China 12%

South Korea 35%

Japan 33%

Source: RAND report 2005

World’s Largest Shipbuilders 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

Hyundai Heavy Industries Daewoo Shipbuilding Marine Engineering (DSME) Universal Shipbuilding Corporation Samsung Heavy Industries Hyundai Samho Heavy Industries Hyundai Mipo Dockyard Mitsui Engineering and Shipbuilding Oshima Shipbuilding IHI Marine United Imabari Zosen Shanghai Waigaoqiao Shipbuilding Dalian New Shipbuilding Heavy Industries Tsuneishi Shipbuilding Namura Shipbuilding STX Shipbuilding Nantong COSCO KHI Engineering Hanjin Heavy Industries Mitsubishi Heavy Industries New Century Shipbuilding China Shipbuilding Corporation Koyo Dockyard Hudong Zhonghua Shipyard Kawasaki Shipbuilding Corporation

24 25

Sanoyas Hishino Meisho Corporation Dalian Shipyard

26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

Bohai Shipyard Sasebo Heavy Industries Sumitomo Heavy Industries Odense Steel Shipyard Shin Kurushima Dockyard Shina Shipbuilding Guangzhou Shipyard International Jiangnan Shipyard Onomichi Dockyard Brodosplit Shipyard Sungdong Shipbuilding Shanghai Chengxi Shipbuilding Aker MTW Werft Gmbh Tsuneishi Heavy Industries Cebu Szczecinska Nowa Stocznia Gdynia Shipyard Yangzhou Dayang Shipbuilding Daewoo Mangalia Jiangsu Yangzijiang Jiangdu Yuehai Shipbuilding Zhejiang Shipbuilding Kanda Shipbuilding Volkswerft Stralsund GmbH ISOICO SADRA-Iran Marine Industrial

Source: Lloyd’s Register Fairplay, World Shipping Encyclopedia January 2006

Shipbuilding Vision To set a global standard within the Maritime Industry allowing data to be: Created Once, Refined and Used Many Times

Product-Oriented Approach Establish the block types in all primary zones from the block breakdown: Accommodation Machinery Space Bow and Stern Cargo Holds

Curved single skin blocks Flat single / double skin blocks Light flat panel blocks

Complex 3D blocks

Benefits of Product-Oriented Approach

Shipbuilding has accomplished: – Increased productivity (5x) – Reduced cycle time (4x to 6x) – Reduced cost (4.5x)

Safety and quality not compromised.

Similar benefits can be achieved in our businesses.

Results of Shipbuilding Evolution Shipbuilding evolution STICK BUILDING

Improved performance Increased output

BLOCK BUILDING

Reduced price Expanded markets Increased profit

PRODUCT ORIENTED

Development Methodology Zone Definition

Overall Approach

Steel Design Base panel for built-up unit

Maximum 5410 mm for assembly on

Outfit Design

panel line Simplify construction at deck to maximize flat built-up panel unitization

Simplify construction at deck and tank top to maximize flat

Block Breakdown / Outfit Unitization

Base panel for built-up unit

Machinery Outfit Unit MM03

of the bulkhead only maximum depth 5410 mm

Alternate location of manholes for access during unit and block

Base panel for built-up unit

assembly stages when depth exceeds 2500 mm

Interface 200/03

O.F. BUNKER & D.S. TANKS

Interface 200/02 Interface 200/01

Machinery Outfit Unit MM02 Secondary panel for double skin block

Base panel for built-up unit

6

3

275 mt 4

Machinery Outfit Unit MM05

GENERAL PANEL CRITERIA FOR PANEL LINE

Outfit Units installed on-block

1 2

2

7

Maximum plate length for panel line is 15800 mm.

4

All panel stiffeners must be in the same direction as

This may be further restricted due to contraints in other areas.

5

Plate thickness range for the panel line is: 8mm to 31mm - Mild Steel

Maximum panel width is 16500 mm. 3 to 5 plates

3

Interface 200/09

STBD MAIN ENGINE & GEARBOX

the plate straking

Interface 8mm to 19mm - High Strength

wide.

2 1

3

Maximum 5410 mm Prefered 3000 mm

Services to be run close to tank top panel for installation at unit assembly stage

275 mt

232 mt

1

Pipe Outfit Unit MP04

200/12

All panel plates must be straked in the same direction.

576 mt

STBD ALTERNATOR

446 mt

INITIAL ZONE PROCESS ENGINEERING Preliminary erection and zone installation sequence.

Interface 200/07

Machinery Outfit Unit MM04

5

6

double skin block

5

Pipe Outfit Unit MP02

PORT MAIN ENGINE & GEARBOX

277 mt Secondary panel for

Principal equipment installed in zone

PORT ALTERNATOR

Interface 200/06

Stbd Side Shell Block

4 Lower Bulkhead Block

Pipe Outfit Unit MP01

Maximum 5410 mm for assembly on panel line

to maximize flat built-up panel unitization

Upper Deck Block Port Side Shell Block

Interface 200/04

Webs on one side

Services to be run close to base panel for installation at unit assembly stage

Simplify hopper construction

Outfit Units installed in zone

Interface 200/05

Base panel for built-up unit

Machinery Outfit Unit MM01

built-up panel unitization.

Maximum 5410 mm Prefered 3000 mm

Interface 200/08

Pipe Outfit Unit MP03 O.F. BUNKER & D.S. TANKS

Interface 200/10

Stbd Double Bottom Block

Machinery Outfit Unit MM06

Port Double Bottom Block

Interface 200/11

Figure 6

Interim Product Database

PIPE PARTS

BLOCK ASSEMBLY

OUTFIT STEEL PARTS

Tack welding portal

Prepare process engineering

Circle welder gantry

Inspection and repair pit

Stiffener welding gantry Dart IV

Stiffener fitting press

25 ton semi-goliath crane Stiffener gantry

1 Panel Assembly 26518

8 Head welding gantry

Assembly 15850

Manufacturing

Stores

SUB ASSEMBLY

2

3

4

5

Seam Weld 15240

Panel Layout 16764

Stiffener Fitting 16764

Stiffener Welding 16764

6 Web Fitting 16764

7 Web Welding 16764

8 Web Welding 16764

9 Unit Inspection 16764

10 Storage 19279

Overall Length of Panel Line 179298

Outfit Facilities

Define interim products FIRST MARINE

International

Ship No.

BLOCK ASSEMBLY PROCESS FLOW CHART

STAGE OF CONSTRUCTION

BLOCK ASSEMBLY

PRODUCT GROUP

WORK AREA or PROCESS LANE

Planning Unit

Generic Example

EP21

Prepared By

Develop Facilities Revision

Approved By Block

Malta Office

Typical Engine Room Side Block

Date

QTY

ENGINE ROOM SIDE BLOCK

BLOCK ASSEMBLY

1

Block Location

Deck unit

Shell unit

Bulkhead unit

UNIT ASSEMBLY

3

Steel

SUB ASSEMBLY

0

Underdeck services

MAJOR SUB ASSEMBLY

O/fit

MINOR ASSEMBLY AND MINOR SUB ASSEMBLY

5 Shell panel

Steel

Deck equipment modules

1

CURVED PANEL ASSEMBLY

O/fit

0 Steel

Bulkhead panel

Deck panel

2

FLAT PANEL ASSEMBLY

O/fit

0 MINOR ASSEMBLY

Deck services

Underdeck services

Vendor Furnished Equipment

MINOR SUB ASSEMBLY

Steel

0 O/fit

2 Steel

Underdeck services

PIPE PARTS

Single side welding gantry

Magnetic bed

MINOR ASSEMBLY

OUTFIT STEEL PARTS

Magnetic bed

Steel Facilities

DIRECTION OF LINE FLOW

PANEL LINE GENERAL ARRANGEMENT

16154 Transfer Car

Identify Block / Unit Families

Design Rules and Guidelines

15

MINOR ASSEMBLY

O/fit

Deck webs/trans

Bulkhead webs

Shell webs

Equipment module foundations and services racks

14

Shipbuilding business drivers Pressure on most major shipbuilders to increase productivity and operational efficiency

– React to increased market demand – Resist competition from new suppliers with lower labor costs

Increasing work with partners: – Sub-contractors – Joint venture partners – Design agents

Distributed working

– Lower cost manufacturing locations

For established industry leaders, a trend towards more higher value, higher complexity ships: – VLCC – LNG

Shipbuilding IT response strategies Investment by most major shipbuilders in key IT systems – Advanced multi-user 3D CAD for design improvement • Extension from CAD to CAD/CAM – Assembly planning – Production support

– Integrated ERP for manufacturing improvement • Integration of production management, purchasing and financial accounting – – – –

Production scheduling Material procurement Material inventory management Production management

Additional IT requirements Effective working with partners – Information sharing and real time visualization and collaboration – Data security, integrity and quality (change control)

More data created and managed in design systems

– Robust means of organizing and managing information storage and flow • Version management • Status management

– Automatic connection between design and production systems

Role of PLM system

Industry comparisons

No of parts

2.5k to 10k

150k to 1.5m

2.5m to 40m

Product Nature

Few (<10) simultaneous, fixed products

Multiple (>10), simultaneous, variant products

Multiple (>20), simultaneous, unique products

Development Process

Design, prototype, manufacture

Design, prototype, manufacture

Concurrent design and construction

Design Collaboration

100’s max

1000’s

1000’s

Management Focus

Production efficiency

Design safety, Production efficiency

Change Control, Work Mgt

Management Technique

Production management

Project management (design), Production management (manuf)

Integrated design & construction project management

Lifecycle

Lifecycle of design

Lifecycle of product

Lifecycle of product

Industry positioning Project Process/Power Shipbuilding

Production Process

Aerospace

Automotive Capital Consumer Equipment Goods

Product Low

Product complexity

High

NASSCO General Dynamics Designing and building naval logistic ships and commercial ships Most Automated Shipyard in the Americas Design and Production Expertise partnership with Daewoo (DSME) further improves competitive position

BP Watson Class

Tote

T-AKE Class

Around the Yard

Around the Yard

Around the Yard

Around the Yard

Around the Yard

Product Information Model

The whole ship consists of objects, e.g. steelwork, equipment, pipes, cables, fittings, etc Access these by system, by zone and / or by assembly Compact, topological database Enables concurrent engineering Ship System

Zone

Assy.

Object Object Object Object Object Object Object

Integrated Object-based Model

Finite Element Analysis

Hull Form

Basic (Scantling) Design Detailed Hull Modelling

Automatic Parts Generation Production Information

Integrated Block Workflow Â&#x192;Structural design and production design hull panels are two views of the same object. Â&#x192;Structural engineers and Production designers can work concurrently at their appropriate level of detail and production splitting can be revised without loosing detail design features

Design Process Overview Data-Centric Design

Components Specification Equipment

Diagrams

Modelling

Production Information

Assembly Planning Â&#x192; Assembly stages manufacture

sub-assembly

unit assembly

paint hall

blocking

erect to ship

Assembly Planning Â&#x192; Pre-outfitting as early as possible

Factory Automation Â&#x192; Generates highly accurate production information needed for automation equipment such as cutting and welding robots

Just-in-time production information

Photo Alstom Marine, Bernard Biger.

Auto Robot Welding & Fabrication

Product Information Model

Part of a Product Information Model, the machinery space of the KDX-2 Destroyer, built by Daewoo Shipbuilding & Marine Engineering Co Ltd., (DSME). Courtesy of DSME

Management of Asset Data Shipbuilding is leading in the use of asset data in complementing it’s CAD usage Product/Project/Process Lifecycle Management (PLM) tools increasingly finding use, especially in Naval shipbuilding Using PLM tools to develop and maintain long term relationships to Owners and Operators for Maintenance and Operations

Data Management â&#x20AC;&#x201C; Old Thinking

CAD Applications

Production CAD Files

Documents

Data

Data Management – New Thinking – Integrated management of design and production data – Data access control – Versioning – Status management openPLM CAD – Document management – Configuration management – Change management Model Documents – Workflow & Work mgmt Database – Project Management – Integration … and more

Digital Shipyard GUI GUIand andNavigation Navigation Structure StructureManagement Management Security SecurityManagement Management CAD CADIntegration Integration BOM BOMManagement Management Document DocumentManagement Management Change ChangeManagement Management Workflow Workflow Production ProductionInterface Interface Integration IntegrationManagement Management Project ProjectManagement Management

open PLM Change Change Management Management Â&#x192; Identifying and assessing the impact of changes to product or project information Â&#x192; All items and documents change controlled, so that no item can be changed without official approval via a change order process

open PLM Document Document Management Management Â&#x192; Manage all electronic and non-electronic documents Content Content Management Management Â&#x192; Managing the creation, update, storage, security and availability of all product and project information throughout the product lifecycle Work Work Management Management Â&#x192; Manage the processes, activities, tasks and resources required to create and maintain all product and project information

open PLM Workflow Workflow Management Management Â&#x192; Workflow modeling allows any process to be modeled, managed, and applied to items or documents

open PLM Collaboration Collaboration Management Management Managing the accessibility, visualization, sharing and markup of product and project information CAD CAD Integration Integration Independent viewing without the source application resident; Intelligent viewing, mark-up, and collaboration of published information BOM/MTO BOM/MTO Management Management Both Design and Assembly planning hierarchies are imported to create baselines to compare differences between Design and Production BOM’s and MTO’s

open PLM Production Production Interfaces Interfaces Â&#x192; Integration with ERP and Planning systems; links to published information (i.e. documents & drawings).

Links to project management for status. Links to workflow management; Links to Production Systems

PLM Technology Positioning Project open PLM - A

Production Process

PLM - T PLM - W

PLM - S

Product Low

Product complexity

High

The Same…BUT Different Most companies expertise is built on knowledge and capabilities in certain areas of skill, competence, and demonstrated success Yet, most projects tend to be “one offs” in execution Shipbuilding is leading the way in learning to use and re-use previous existing designs in new projects or “products” Implementing the “Interim Product Model”

Sisterships A Planned Series of Ships From a Common Design Interim â&#x20AC;&#x153;Masterâ&#x20AC;? Product Model

But With Design Differences

Sistership Support A Master-Slave relationship with individual effectivity rules Controlled transfer to Slave Product Information Models Interim “Master” Product Model

Sistership Benefits Improved Management Control Improved Traceability Automated Data Transfer Between Master and Slaves Less Prone to Errors Significantly reduced costs for multiple “similar, BUT different designs Lower Lifecycle and O&M costs

Use of Standards FIATECH has been leading the charge for the adoption of standards within the Large Capital Projects marketplace, especially with ISO 15926 The National Shipbuilding Research Program (NSRP), along with the Navy, is leading a similar effort in shipbuilding, with ISO 10303 and STEP There is synergy to be gained by learning from each organization’s efforts

Navy Product Data Initiative

National Shipbuilding Research Program

Specification Working Group Vision More capable ships will be delivered at a lower cost, with improved design-build cycle time, and with a significant reduction in the cost of changes. These gains will be achieved because: Lower cost Each Navy shipbuilder will be able to maintain site-compliant IPDE solutions; BUT Yards choose - Navy will NOT dictate which IPDE No need to switch from program-specific IPDE to program-specific IPDE Individual IPDE components can be upgraded / replaced without major disruption Software cost and development risk for incremental IPDE improvements can be spread across multiple programs / yards for shared benefit

Improved design-build cycle time

Information will be readily communicated to other yards, suppliers, Navy, and classification society reviewers.

Enhanced Sharing of Best Practices (e.g., Design Practices) across the Enterprise Best-of-breed software, including third party software, can be selected / shared

Reduction in the cost of changes

Non-value added labor will be reduced searching for, transforming, and validating ship info

Specification Working Group Scope Configuration Management

• Configuration Unites (class, slight, hull, system, assembly, Piece Part…)

• Access Control

Change Management

• Status dependency management

Collaboration • • • • • •

Design in context (all disciplines working in the same model) Planning ILS Construction Design reviews and oversight (internal and external) Interface requirements

In service support requirements

• As maintained product model/configuration

Interoperability

• Minimum data elements for various objects • Data Exchange via Standards and Open Archetype (ISO 10303, STEP) • ISO 15926 ?

Benefits of Product-Oriented Approach

Cost Schedule

Traditional (US)

Product-Oriented (Korea and Japan)

$150M

$33M

36 mos.

7-10 mos.

While maintaining a superior record for quality and safety

ALCAN Gove Australia $2.4 B aluminum refinery expansion Modular construction using Pre-Assembled Modules (PAMS); up to 1,700 tons each PAMS are completely fabricated and fitted out offsite (at shipyards in 3 countries); delivered to site as complete and ready to install modules No interruption of day-to-day operations at the existing refinery operations Used integrated RFID tagging, installed at the shipyards; Alcan can control which individual item belongs to each specific PAM throughout the whole facility

Lessons Learned ??

Design for Construction/Production/Assembly Block Layout/Design/Construction PLM – Change Management – Workflow Management – Automated Production

Global Collaboration – Design – Construction/Fabrication – Real-time visualization/ simulation

Lessons Learned ??

Object-oriented, Data-centric Assembly Planning Production Support Integrated ERP Integrated Construction Management Comprehensive Asset Management “Sistership” concept applies to most all EPCI’s, and O’O’s “Product” oriented approach

Roadmap to “Product” Approach Consider several projects of a similar type, and look for block families Study the degree of similarity of the block families – Can they be made uniform?

– Is there a product family?

– Or, could one be developed?

Build up the block family from products (unique project from common elements)

Roadmap to “Product” Approach Capture in digital format Manufacturing/Construction design – – – – –

Movement of piece Centralized scheduling Needed capabilities to match takt time Automation of routing, cutting, marking, assembly Subassemblies and intersecting product lines

Assembly of products Fit-out

In Summary…

There is much that we can learn from shipbuilding; more than covered here But, there is also much that they can learn from us – like ISO 15926 to start…