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1 1 Simulation toolset for the shipbuilding industry dimensions : length (hall): 370 m width (hall): 101 m height (hall): 60 m length (dock): 358 m width (dock): 39 m block assembly 2 Meyer Werft

2 1. Simulation toolset modelling tool visualisation tool 2. The virtual shipyard evaluation tool 3. analytic methods optimisation Design of experiments (DOE) 3 objectives Supported by 4 long term simulation resources & due dates Tool : em Plant optimisation BB, GA... long term process planning due dates & capacities Tool : AS project oriented planning medium term sim. resources & due dates Tool : em Plant Production oriented planning medium term planning due dates & capacities Tool : AS >1 year 12 3 months weeks - days strategic (long term) tactical (medium term) operational (short term) planning / simulation at JLM short term simulation resources & due dates Tool : em Plant optimisation BB, GA... optimisation BB, GA... detailed planning control (PPC) (FP) PPC (production control centre) data time management information system (MIS)

3 problems and focusses development of a simulation toolset shipbuilding customized tool libraries connectable models holistic simulation utilisation of data utilisation of simulation models ease of use 5 focusses within the project data management sequence of simulation models long term simulation panel line utilisation of space concept study toolset library shift plan space \ area evaluation Gantt 6 simulation tools (toolset)

4 Internet : Mail : 7 contact simulation at Meyer Werft 8 years experience in appliance of simulation simulation software: WITNESS simulation of subdivisions (e.g. TBS) simulation of conceptual solutions (e.g.cutting center) specially programmed simulation applications (e.g. area utilisation of block assembly in C++) since August 1998: use of Simple++/eM-Plant since August 1998: BMBF project Simulationstoolset für die Schiffbauindustrie BMBF FKZ 18S0104 B 8 simulation at Meyer Werft

5 Problemstellungen und Schwerpunkte Entwicklung eines Simulationstoolset Schiffbauspezifische Bausteinbibliotheken Integrierbare Modelle Ganzheitliche Simulation Datenverwendung Modellverwendung Benutzerfreundlichkeit 9 Schwerpunkte im Simulationsprojekt intermediate results: product structure long term simulation utilisation of space toolset panel line strategic workflow and layout planning presentation of results creation of tools and objects data structure 10 intermediate results

6 What is a toolset? focus: simulation toolset simulation toolset for the shipbuilding industry evaluation tool What is a toolset good for? Library of flexible tools visualisation tool modelling tool effort for model creation Without the Toolset With the Toolset Degree of model specialisation 11 simulation toolset for shipbuilding focus: tool libraries creation of a tool library for the shipbuilding industry specific libraries of simulation tools for: a) automotive industry b) chemical industry Tool library for the shipbuilding industry? 12 tool libraries

7 focus: modular models modular linking partial of modular models partial of the models Yard to a complex shipyard model TBS cutting center cutting center TBS dock block block assembly panel line assembly dock section panel lineassembly section assembly 13 modular models focus: data transfer centralised data management planning (static) target actual production data target actual Simulation model (dynamic) order new target 14 data transfer

8 focus: use of simulation use of simulation models on: a) management level b) planning level c) foreman level requirements for the simulation system: - user-friendly interfaces - visualisation (3-D) of models - graphical presentation of results - enable interactive working with models 15 ease of use focus: use of simulation models product planning continuous use of simulation models factory layout planning Z U L A G E P R O J E K T P O L production planning CHRONOLOGIE DER BAUDOCKBELEGUNG 98 1.Quartal 98 G Januar 98 R S.646 O 32 B P L A N Februar 98 U S.646 N G Maerz 98 S.645 S W E R F...Vormonats-Soll...Monats-Soll...Monats-Ist T F3 == 16 use of simulation

9 focus: software technique involvement of experts know-how - in data bases - in AI- systems (neural network) - in expert systems inclusion of utilisation of areas optimisation of production processes - with genetic algorithms - with design of experiments increase of closeness to reality improvement of processes 17 software technique 18 production planning

10 An imation Gant-Auswe product Hierarchie model Modell geometric model generation of simulation data interactive creation of alternative schedules transparency of simulation data 19 product structure model controls animation of the simulation evaluation: Gantt evaluation: capacities support of investment planning planning of orders transaction 20 long term simulation

11 tool: tack_profiles model based on tools model basic modules Basic modules tool tack_profiles tack_profiles library Panel line 21 tool library panel line in-house development basic tools evaluation tools maintenance simulation tools external development data management / data interfaces simulation tools u.a. optimisation additional tools different purposes 22 tools and objects status quo

12 object: space 3-D visualisation business classes Eingang Ausgang GUI classes Montage Umlagerung Ausrüstung Eingang / Ausgang Raum 23 utilisation of space (principle and example) Was ist Simulation? Simulation ist ein Verfahren zur Nachbildung eines Systems mit seinen dynamischen Prozessen in einem experimentierfähigen Modell, um zu Erkenntnissen zu gelangen, die auf die Wirklichkeit übertragbar sind. Mit Hilfe der Simulation kann das zeitliche Ablaufverhalten komplexer Systeme untersucht werden. (VDI 3633) 24 definition of the term simulation (VDI 3633)

13 contacts: Peneewerft, MTW, FSG, TUHH, Fraunhofer workshop (Tecnomatix and Meyer Werft) : subject: simulation in shipbuilding industry em-plant users meeting: subject: simulation in shipbuilding industry STG Meeting : subject: simulation tools for shipbuilding industry 25 Contacts and presentations 26 visualisation of results

14 overview space object: consideration of parts geometry simulation of assembly and storage transactions consideration of assembly and outfitting times integrated 3-D visualisation full integration into the em-plant environment extensive statistical functions lifecycle-logfile for each space and part parameterisation of the object via dialogboxes integration of to-bin strategies (rotate, batch, rearrange) 27 utilisation of space 28 strategic workflow and layout planning (panel line)

15 product working plan resources ID : 02_Kran em Plant DB front end Datenbank database P WP R model Vx = 5 m/min Vy = 10 m/min EDP 29 concept: data structure product model CAD CATIA model 30 CAD data transfer

16 31 networks 32 attributes of resources

17 object: shift GUI classes business classes DB classes 33 object structure space obj. control system computer life cycle obj. shift obj. 34 modelling using objects (space)

18 An imation Gant-Auswe product structure production steps resources dialog box: scheduling long term model Meyer Werft dialoggantt: box: basic dates ID_Bauteil Gantt: block routing Aug Sep Oct Nov ID_Bauteil Jahr Kalender10 Jahr 2001 Kreuzfahrer TestMontage_656 TestMontage_649_1_35 Hotelblock Schiffsmontage-I Hotelblock Bauabschnitt Bauabschnittbau Schiffsmontage- Bauabschnitt TestMontage_656_2 TestMontage_649_1_11 Hotelblock Bauabschnittbau Bauabsc TestMontage_656_2_1 TestMontage_656_2_62 Hotelblock Bauabsc Kreuzfahrer TestMontage_649 TestMontage_649_1_14 Hotelblock Schiffsmontage-I Schiffsmontage-II TestMontage_649_1 TestMontage_649_1_27 Ap Ma Ju Ju Au Se Oc No De Ja Fe Ma Ap Ma Ju Ju Au Se evaluation: capacities Report TestMontage_656_63 Planungsvariante TestMontage Volumenblock Ersteller: krause TestMontage_656_64 Ausrüstungsblock shift plan TestMontage_649_1_28 TestMontage_649_1_98 TestMontage_649_1_30 Hotelblock Hotelblock MR-Mod TestMontage_649_1_31 Hotelblock Report Ersteller: krause 35 scheduling and long term simulation shipyard model (logic level) Shipyard model 3-D view 36 modelling using objects

19 1. simulation toolset modelling tool visualisation tool 2. the virtual shipyard evaluation tool 3. analytic methods optimisation design of experiments 37 objectives Gefördert vom 38 visualisation of results

20 data management toolset shift plan space \ area simulation tools models evaluation and visualisation 39 simulation tools block assembly 40 Lego principle

21 41 Block assembly in the dock techn. specifications length over-all width measurement machine power velocity cabins with balcony 382 outside cabins 653 inside cabins 268 passenger capacity m 32.2 m 76,000 BRZ 79,900 h.p. > 24 knots 42 Aurora

22 1. log-in 2. selection of a model 2.1 administration of users 2.2 administration of models 3. start model development or runtime license 43 administration of models and users 1. method documentation - method manager (80 %) - documentation guideline (80 %) 2. tool and object documentation (60 %) - tool and object data base (60 %) - documentation guideline (60 %) 3. model documentation - application documentation (20 %) - documentation guideline (20 %) Handbücher 44 documentation concept

23 topologies: blocks and sections watertight compartment deck / fire zone extension product model registration and documentation of tools Show progress of processing registration and dokumentation of models maintenance of tools manipulation of inheritance search in method source code filter functions for tables frequently used general functions Dialog module for object selection 46 basic toolset

24 data base interface: select alternative schedule, write back schedule situation shift plan: consideration of labour time per resource basic dates: check of milestones constant block assembly rate, achieved by balance calculation scheduling for blocks and sections scheduling: fixed dates stay untouched evaluation: illustration generated with the Gantt-tool 47 scheduling tool intention: construction of complex graphical interfaces for model control (cockpit) 1. standard dialog em-plant simple input boxes messageboxes 2.utilisation of ActiveX control elements a) general b) specialised tree: list: table: shift plans: 3. creation of a control element library 48 graphical user interface (GUI)

25 presentation mode: preset and definable formats use cases: presentation of schedules from planning, simulation and optimisation additional functions: miscellaneous filter functions headers and footers for additional information (time bar, legend etc.) data base interface (provide settings for other applications) short term scheduling: piece part and section production long term scheduling: shipyard occupancy, stage of construction per ship middle-term level: block assembly, block assembly rate 49 Gantt - Baustein Hardware - Configuration 4 Laserplotter DinA3 4 Plotter DinA0 PROJECT: - CATIA - 3 RS/ P, Mod 140 and 150 TECHNICAL DEPARTMENTS: - CATIA RS/ P, Mod 140 and Mod 150 PLOSSYS: - Plot queue manager PRODUCTION PLANING: - AS V Users Optical Disks 35 Time Check Terminals AS/400 User 350 User 80 Printer Pipe Store CMOS III Central Control System AS/400 Modell 640 SP2-SYSTEM: -4 Nodes GB Capacity PROJECT: -NAPA -3 NT Workplaces SIMULAION: - 6 NT Workplaces OFFICE APPLICATION: PC Workplaces (Win95/NT) AS/400 Modell D10 PRODUCTION-SERVER 50 Container Store High Base Warehouse DNC Profile Roboter System DNC Cutting - Workshop

26 components & objects Datenbaustein Ressourcenklassen Leitrechner Schnittstellen Modelle Weiteres Vorgehen : Erweiterte Netzplantechnik: Parallele und alternative Wege Modularisierung von Komponenten und Modellen Visualisierung 51 Toolset Schiffbauliche Vorfertigung Optimierung I Optimierung II Basistoolset Dokumentation Tools und Objekte Benutzer Oberflächen (GUI) Anwender und Modellverwaltung Kontakte Vorfertigung 52 Simulationswerkzeuge II (Toolset)

27 simulation model simulation run view of 3-D model 53 simulation model 54 model

28 55 the virtual shipyard data model evaluation 40 % 30 % 30 % ID : 02_Kran Vx = 5 m/min Vy = 10 m/min Aufwand für die Modellerstellung Modellspezialisierung simulation WBS, process definition, PDA simulation toolset MIS system, applications 56 shares in development efforts (simulation)

29 :27 Product model product model CATIA CAD model :27 CAD data transfer

30 topologies: blocks/sections watertight compartments deck/fire zone :27 extension product model 8 corners model YZX E8 E7 E6 E5 E4 E1 E3 E :27 Geometric model (8 corners)

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