Simulation in Production and Logistics at...

Simulation in Production and Logistics

at FlensburgerExperiences from the Future

Dirk SteinhauerHead of Simulation Team

Department for Research and Developmentsteinhauer@fsg-ship.de

APPLIED SIMULATION – A SYMPOSIUMLyngby, 07.11.2013

Flensburger Shipyard

Company Data of Flensburger Shipyard

� Established in 1872� 730 employees� 3-4 ships p. a. up to 220m in length� Turnover app. €200Mio� Key competences:

• Steel production• System integration• Research and development

Flensburger‘s Product Mix

EGV Class 702

Ro Ro 2700

Ro Ro 3900

Ro Ro 2700 for AWSR

Ro Pax 1500

Con-Ro 1000/4600

RoPax Ferry for BC Ferries

Ro Pax 3200/650

Ro Pax 2400/600

Ro Ro 3200

Current Orders at Flensburger Shipyard

ConRo for Oceanex

2 project cargo vessels for Rolldock

2 seismik ships

Characteristics of Production in Shipbuilding

Complex product

One-of-a-kind production

Compactproduction

Chaining of different production principles

Building dimensions

Inhomogeneity of utilisation

0

10

20

30

40

50

1 2 3 4 5 6 7 8 9 1 0 1 1 1 1 1 1 1 1 1 20

Variety of parts

Simulation: Dynamic Model of Production System

System (production/log.)

plants / transp. meansworkers

workplaces stock

process

Schleifen

Schweißen

Montieren

Dynamic Model

Input data

The Plasma Cutting Planton the Panel Line

Simulation Model of the Plasma Cutting Plant

The Simulation Tool for Cutting PlantsSTS_CuttingPlant

Programs for Cutting Plants

Control of the modul cutting plant

Interface toNum. Code

�Plate owns attribute NC-File

�NC-File is read and translated

Generating Num. Code

�Plate owns geometr. attributes

�NC-File is calculated from geometrical data of plate and panel

Reasons for Using Simulation in Production and Logistics

� Detailed analysis of production or logistic systems

concerning dynamic relationships and interactions

� Cost efficient trials without any risk

• New production facilities or concepts

• New ships

• New plans

� Transparency of processes

� Objective basis for communication

� Planning reliability

� Flexibility in planning

Application Fields for Simulation ofProduction and Logistics at Flensburger

Facility layout planning

Production planning

Production flow

Civil engineeringPort logistics

Loading / dischargingof ships

Offshore wind parks

Development of Simulation ToolsUsing Plant Simulation (Siemens PLM / Tecnomatix)

Simulationtools

Transportcontrol

Crane

Shift calendar

Pre-Production

Applications

Logistics

Ship‘s Logistics

Outfitting

Final Assembly

Philosophy of STS (Simulation Toolkit Shipbuilding)

� Efficient and effective model building� Implementation of well-proven modelling approaches� Provision of best practice scenarios� Individual adjustability of models

• Interfaces for user rules and specific settings

� Cooperative development• SimCoMar• SIMoFIT• Technical University of Berlin

� Interbranch applicability• Construction industry• Plant construction industry• Machine building industry

Structure of STS(Simulation Toolkit Shipbuilding)

Steel

BasicsLogistics

Transport

Material

Outfitting Interior fitting

- Space- Model administration- Personnel control- Statistics- ...

- Cutting machines- Welding machines- Assembly sites- Painting facilities- ...

- Storage control- Supplier- Packaging- ...

- Steel parts - Steel elements- Outftting parts- ...

- Floor conveying syst- Cranes- Roller conveyors- Streets / crossings- Transport control

- Outfitting sites- Assembly control- ...

- Compartment- ...

Structure of STS Including Add-on Libraries (Simulation Toolkit Shipbuilding)

STS_OWEA- Offshore windpark

installation

STS_PortLog

STS_ShipLog

- Container terminals- RoRo terminals- Ferry terminals

- Load and discharge ships

Steel

BasicsLogistics

Transport

Material

Outfitting Interior fitting

- Space- Model administration- Personnel control- Statistics- ...

- Cutting machines- Welding machines- Assembly sites- Painting facilities- ...

- Storage control- Supplier- Packaging- ...

- Steel parts - Steel elements- Outftting parts- ...

- Floor conveying syst- Cranes- Roller conveyors- Streets / crossings- Transport control

- Outfitting sites- Assembly control- ...

- Compartment- ...

Examples for Tools of STS(Simulation Toolkit Shipbuilding)

Crane

Space

Outfittingcompartment Cutting plant

Stiffenererection portal

Statistics

Transport control

Assemblycontrol

Steel

BasicsLogistics

Transport

Material

Outfitting Interior fitting

- Space- Model administration- Personnel control- Statistics- ...

- Cutting machines- Welding machines- Assembly sites- Painting facilities- ...

- Storage control- Supplier- Packaging- ...

- Steel parts - Steel elements- Outftting parts- ...

- Floor conveying syst- Cranes- Roller conveyors- Streets / crossings- Transport control

- Outfitting sites- Assembly control- ...

- Compartment- ...

Characteristics of the Tool STS_Crane

Management of transports by cranes of several types (gantry, bridge, container, construction, ...)

� Easy use• Method .request(part, target)• Qualified and available crane vehicle is selected.• Crane motion is generated automatically.

� Option: Specification of individual transports:• Linking of gantries for heavy transports• Turning of parts• Personnel for transport• Definition of transport path• Mobile crane on vehicle• ...

Different Crane Types ModelledUsing the Tool STS_Crane

Tool STS_Space for Space Allocation

� Allocation of space by objects considering• Size or geometry (shape)• (Safety) distance required

� Definition of• Areas for special purpose (building site, storage area, ...)• Blocked areas (temporally if necessary)

� Various allocation rules available• Starting point and direction• Circular search• Closest to specific object• Maximum available space• ...

The Tool STS_ProcessControl

Control of several parallel assemblies considering

� Standardized or individual process patterns

• Selection of worksteps• Sequence of worksteps

� Consideration of part characteristics

� Allocation of required qualifications

� Hard and soft assembly constraints

� Spatial constraints

SimCoMar: Simulation Cooperation in the Maritime Industries

� Flensburger Schiffbau-GmbH & Co. KG

� Blohm & Voss Nordseewerke GmbH

� Fr. Lürssen Werft

� Howaldtswerke – Deutsche Werft

� Technische Universität Hamburg-Harburg

• IPM - Institut für Produktionsmanagement und –technik

� Technische Universiteit Delft (NL)

� Center of Maritime Technologies e. V.

� ANAST – Universität Liège (B)

www.simcomar.com

SIMoFIT – Simulation of Outfittingin Shipbuilding and Civil Engineering

� Simulation of Outfit ting Processes in Shipbuilding and Civil Engineering� Cooperation of shipyards and civil engineers� Basis for development: STS (Simulation Toolkit Shipbuilding)� Constraint based simulation: generic definition of constraints

www.simofit.com

Fields of Activity for Material Flow Simulation at Flensburger

Production Planning

strategicLayout planning

tactical

operative

today time

Logistics

Production Development

Ship Harbour

Evaluation of Concepts for a New Part Fabrication

• Replacement of old plant (under water)• Cutting and

grinding, marking, signing (both sides)• Throughput at least 1,5 of initial situation

Simulation of the Part Fabrication

Development of a New Profile Cutting Line

SAPP - Simulation Aided Production Planning

todayPlanning horizon

StrategicPlanning

� Definition of suitable flow

� Raw product data

TacticalPlanning

� Verification of monthly plan

� Real product data available

� Raw status needed

OperativeControl

� Realisation of plan and reaction on deviation to plan

� Detailed online status necessary

Simulation Aided Production Planning (SAPP)

� Verification and improvement of program plan in early planningphase• Feasibility studies• Bottleneck analysis• Analysis of robustness• Improvement by changing building strategies, sequences, ...• Definition of dates and sequences

� Weekly adjustment of plan• Final adjustment of manning level and dates based of production

status

� Reaction on disturbances• Evaluation of strategies to get back to the plan

Data Flow to Simulation

SimulationmodelSimulation

database

MARSMaterial control

ALMANesting, NC-files

NUPASDesign

Productionstatus

ACOSScheduling

Product data

Personnelplanning

Data periphery

DigiMethBuilding methods

Input data

Output data

SimulationmodelSimulation

database

MARSMaterial control

ALMANesting, NC-files

NUPASDesign

Productionstatus

ACOSScheduling

Product data

Personnelplanning

Data periphery

DigiMethBuilding methods

Input data

Output data

Presentation of Results inSimulation Database

Estimated deviation of dates plan/simulation

Estimated utilisation of production stations

Using Simulation for Planning of the Panel Line

Workers

Reduction from 22 to 14 workers

Difference of production to plan [d]

Time of implementation

� Transfer of production strategies from the simulation to the shop floor

� Defining personal by simulation� Scheduling by simulation

Continuous Validation of the Simulation Results

Diffrence between simulated dates and real production datesin pre-production

Simulation in the Program Planning of a RoRo-Series

Simulation of production of three ships for program planning10 months ahead of production

Forecasted schedule variance at the beginning of the project

Forecasted schedule variance after using simulation

SAPP Applications at Flensburger

Profile production

Plate production

Block production

Hull erectionPainting

Logistics

Pre-production

Planned Plate Storage in Denmark

Pax-Logistics for BC -Ferries

Concept for handling of additional material building RoPax vessels:� External storage� Shuttle traffic connecting external

storage and shipyard� Buffer sizes and locations at FSG� Size and control of

transporter fleet

Goal:Simulation basedcontrol toolfor logistics

Simulation Model of the Pre-Production

Platecutting

Platewelding

Profilemounting

Outfittingassembly

Section assembly and

outfitting

Welding profiles and

outfitting

Section welding

Simulation of Closed Section and Block Assembly

Space allocation Assembling processes

Simulation Model of Block Assembly

Simulation Model of Flensburger Shipyard

Simulation Model of Refurbishment Proceduresin a Passenger Zone

SIMGO –Simulation Based Optimization

Inputdata

Simulationmodel

Optimisingtool

Optimisedresult

FKZ: 03SX219

Results Parametervariation

Simulation Based Optimizationin Part Fabrication

Blasting andmarking machine Cutting machine

Bottleneck cutting machine has waiting time� Sequence has impact on throughput

Optimization runs to minimize production time:

Research Project HEPP – High EfficientProduction Planning for Prototype Competence

� Goals:• Methods to prepare, check and improve the data basis for

planning especially in early project phases• Continuous simulation aided production planning in

shipbuilding

� Term: 01.10.2013 – 30.09.2016� Partners:

• FSG (Coordinator)• Meyer Werft• SimPlan AG• Center of Maritime Technologies e.V.• Ruhr University Bochum• Technical University Hamburg-Harburg

Simulation of Logistics at Flensburger

Simulation of Loading and DischargingSimulation of

Logistic Chains

Route and fleet simulation

Simulation of Port Logistics

Ferry terminalsRoRo terminals

Simulation of Discharging and Loading a RoRo Carrier

Simulation of a Planned Ferry Terminal

Simulation of Container Terminals

Simulation of a Container TerminalOperated by Straddle Carriers

Simulation of an Inland Container Terminal in Berlin

Simulation Model of the Logistics for Wind Park Installation

Thank youfor your attention!

Dirk Steinhauer

Head of Simulation Team

Department of Research and Development

steinhauer@fsg-ship.de