Jong Hun Woo

A Simulation-Based Capacity Analysis of a Block-Assembly Process in Ship Production Planning

A capacity calculation and process analysis is a very important part for the entire ship production planning. Ship`s production plan is set up with a concept that the product is produced based on the capacity achievable by the processes while general manufacturing sets up the production plan based on product lead-time. Therefore, in case the calculation of capacity for each process of shipbuilding yard is different from actual conditions, a series of production plan - ship table composition, dual schedule plan and execution schedule plan, etc - may accumulate errors, lose reliability of planning information and cause heavy cost deficit in this course. In particular, in case of new shipbuilding yard, stocks between processes are built up and half blocks are not supplied in timely manner, and that is sometimes due to the clumsiness of the operator but it is more often because of the capacity to execute each process is not logically calculated. Therefore, this paper presents the process to calculate the assembly leadtime and assembly process capacity for shipbuilding yard assembly factory. This paper calculated the block type for calculation of assembly lead time based on block DAP(detailed assembly procedure), and introduced cases that calculate production capacities by assembly surface plate by considering the surface plate occupied area of the blocks that change depending on assembly field area and assembly processes through assembly simulation.

Development of a Design Framework for Simulation Based Shipyard Layout

Abstract In recent days, global shipbuilding companies have been increas ing their productivity or expanding their shipyards for a large amount of orders. Though, few researches about the shipyard layout designs have been studied. This research presents a simulation-based shipyard layout design framework to resolve the problems of the shipyard layout design. The shipyard layout design framework was developed on the basis of systems engineering method. The disciplined system engineering technique was guided by ISO/IEC 15288 during the planning phase of the shipyard layout design framework development. This framework suggests that how efficient and effective shipyard layout design could be got, that can satisfy the stakeholder of the layout. Furthermore, it is recommended that how the proposed shipyard layout should be verified and validated by digital simulation model. It is expected that the framework will contribute to not only the improvement of the existing shipyard but also the construction of the new shipyard.

Systematisation of ship production management and case study for ship block assembly factory

Recently, the speed of change related with enterprise management is getting faster than ever owing to the competition among companies, technique diffusion, shortening of product lifecycles and excessive supply in the market. For example, the requirements (such as delivery date, product quality, etc.) of the ship owner is getting particular and the needs for the new product are being emphasised. This paradigm shift emphasises the rapid response rather than the competitive price and also flexibility and agility rather than effective and optimal perspective for the domestic shipbuilding company. So, domestic shipbuilding companies have to secure agile and flexible ship production environment that could respond to the change of market and the requirements of customers to continue a competitive power in the global shipbuilding market. In this article, a standard ship production management is defined by extracting the common factors from the Korean major shipbuilding companies’ systems. Also, a ship production management and system is proposed through detailed analysis of the activities and the data flow of the Korean major shipbuilding companies’ systems. And, the system functions for the strategic ship production management are investigated through the business administration tools such as performance pyramid, value driver tree and balanced score card. Finally, the case study was conducted for the development of the simulation system that is able to generate and validate a production planning data of the block assembly factory.

A Shipyard Layout Design System by Simulation

Shipyard design and equipments layout problem, which are directly linked with the productivity of ship production, is an important issue serving as reference data of production plan for later massive production of ships. So far in many cases, design of a shipyard has been relying on the experienced engineers in shipbuilding, resulting in sporadic and poorly organized processes. And thus, economic losses as well as trials and errors in that accord have been pointed out as inevitable problems. This paper extracts a checklist of major elements to fine tune the shipbuilding yard designing process and the input/output data based on the simulation based shipbuilding yard layout designing framework and methodology proposed in existing researches, and executed initial architecture to develop software that integrates all the relevant processes and designing tools. In this course, both user request and design data by the steps are arranged and organized in the proposed layout design template form. In addition, simulation is done based on the parent shipbuilding process planning and scheduling data of the ship product, shipbuilding process and work stage facilities that constitute shipbuilding yard, and design items are verified and optimized with the layout and equipment list showing optimal process planning and scheduling effects. All the contents of this paper are based on simulation based shipbuilding yard layout designing methodology, and initial architecture processes are based on object oriented development methodology and system engineering methods. 접수일자: 2008 년 4 월 9 일, 승인일자: 2008 년 6 월 3 일 † 교신저자: syj092@snu.ac.kr, 018-275-1799 시뮬레이션 기반 조선소 레이아웃 설계 시스템 개발 대한조선학회 논문집 제 45 권 제 4 호 2008 년 8 월 442 ※

Development of an evaluation framework of production planning for the shipbuilding industry

ABSTRACT Shipbuilding competitiveness can be improved by implementing a production planning system that reflects production environments and can achieve a high degree of completion. Unfortunately, even South Korean shipbuilders, which are the world’s most competitive, lack relevant research on the objectives, and a comprehensive evaluation method for the systemisation of the production planning process and the results of production planning. This study proposes a comprehensive ship production planning process by analysing production planning tasks executed in major South Korean shipyards. In addition, it proposes an evaluation framework and an evaluation system to assess production planning based on an integrated production planning process. The evaluation framework consists of the planning stage and the stage of operation in a company, thereby enabling evaluation of production planning from multiple perspectives. In addition, while establishing the evaluation system for the results of production planning in large-scale shipyards, the study presents the core items necessary to introduce and build a real evaluation system through the framework.

Computational Shipyard Dynamics

Early simulations focused mainly on virtualizing the shipyard itself and the approach in terms of production management that focuses on improving productivity was hardly sufficient. For systematica ...

A ship block logistics support system based on the shipyard simulation framework

The block logistics in shipyard accounts for a considerable proportion of the production cost. And further, it used to effects serious delays on the shipbuilding processes in typical cases. However, the planner hardly incorporate the logistics into serious consideration due to its various restriction at the stage of production planning. In this paper, a simulation-based ship block logistics support system is suggested. With which, the block logistics is to be simulated according to the various production plans and operational strategies of shipyards. The suggested system will allow planners and the management to determine the current state of logistics and to have the insight of improvement as well, reflecting effectively the constantly revised production plan of the shipyard. In addition, the system can be easily adapted to the any shipyard, since it has been developed based on a shipyard simulation framework which can be extended properly with its scalable components.

A Study of Piping Leadtime Forecast in Offshore Plant’s Outfittings Procurement Management

2010년대 심해 자원 개발에 대한 관심이 증대 되면서 해양플 랜트 수요가 증가하였다. 당시 상선 수주 부진을 겪고 있던 국내 조선사들은 글로벌 해양플랜트의 수요를 거의 독점하다시피 하 여 건조물량 확보에는 성공하였다. 하지만 부작용은 수주된 해양 플랜트가 본격적으로 생산되기 시작하면서 나타났는데, 2014년 부터 2015년까지 해양플랜트 부실로 총 8조5000억원 가량의 손 실을 냈다 (Kim, 2015). 이러한 문제는 원인을 설계와 생산의 관점에서 두 가지로 나 눌 수 있는데, 첫 번째는 설계엔지니어링 역량 부족으로 인한 저 가수주에 따라 제작기간 중에 빈번한 설계변경을 들 수 있다 (Seong, 2014). 해양프로젝트가 대형화, 고사양화로 난이도가 높아지는 상황에서 수주를 턴키방식으로 진행하였고 건조 경험 부족과 까다로운 검사 기준은 설계가 자주 변경되는 현상을 발생 시켰으며 이는 생산일정 지연과 건조비용 상승으로 이어졌다. 또 한 두 번째 원인은 기존의 상선과 해양플랜트의 제조방식의 차이 를 들 수 있다. 기존의 상선의 경우 후행작업에 비해 선행작업의 비중이 월등히 많았기 때문에 후행작업에 대한 설치계획 및 설치 순서가 정형화되지 않았으나 해양플랜트 산업의 경우 안벽에서 이루어지는 후행의장작업의 비중이 늘어남에 따라 기존의 공정 시스템이 이를 수용하지 못하게 되어 일정지연이 발생하게 된 것 으로 볼 수 있다. 본 연구는 2가지 요인 중 생산적 측면의 관점 에서 문제를 다루고자 한다. 특히 의장품 중 후행작업에서 가장 많은 지연이 야기되는 배관 제작 및 설치 공정의 리드타임 예측 을 통해 조달관리의 수준을 높이는데 목적으로 두고 연구를 수행 하였다. pISSN:1225-1143, Vol. 53, No. 1, pp. 29-36, February 2016

Construction of standardised data structure for simulation of mid-term scheduling of shipbuilding process

In shipbuilding, the scheduling system is susceptible to sudden changes and thus proves to be difficult to predict in advance. Computer-based simulation is commonly utilised to overcome the challenges of estimating workloads and resulting processing times. However, the main drawback of this solution is its limited applicability; in most cases, each shipyard requires a specific, customised simulation. By standardising planning data of the mid-term scheduling system, as proposed in this paper, the inefficiencies of the current model of simulation can be addressed more effectively. To present this alternative approach, this paper will begin with an analysis of the structure of complex planning data system and then proceed to construct a common structure that facilitates the simulation by converting the custom data into standardised format. This involves the development of an extensible markup language (XML)-based translator and the verification of developed data structure, which is carried out in net-based application.