Global Industrialisering & Produktkonfigurering

Transcription

1 Global Industrialisering & Produktkonfigurering Virksomheder i netværk Trondheim Maj 2004

2 Agenda 1. Introduction to Aalborg Industries 2. Why Product Configuration? 3. The Standardisation Process 4. Challenges 5. Demonstration of Configuration Tool

3 Aalborg Industries Facts Global market leader (Marine boilers and energy equipment) Owned by Danish investors group headed by Axcel Production area: 80,000 m² in the Aalborg Industries Group Employees AI Group : 1,412 in Aalborg blue-collar workesr 230 white-collar workers Quality certifications ISO 9001:2000 Quality Management System (since 1989 ASME Boiler and Pressure Vessel codes S and NBBI s R since 1986 LRS, DNV, BV, NK, RINA, CS, KS, ABS, AT.

4 Aalborg Industries History 1912 Aalborg Shipyard established 1919 First Aalborg boiler (Scotch marine type) 1930 s New types of boilers developed 1937 Danish J. Lauritzen Holding (shipowners) acquired Aalborg Shipyard 1944 First power station boilers built 1978 First after sales service company established in Singapore 1980 Production of large industrial power plants 1988 Burner company acquired (KB burners) 1990 Heat exchanger / incinerator company acquired, A/S Vesta 1995 The Sunrod Group (marine boilers and heat exchangers) acquired from ABB 1997 Zurn Energy Division (HRSG & Keystone Package Boilers) acquired from Zurn Industries Inc Pipemasters Oy (UNEX TM marine and industrial boilers) acquired from Finnyards Oy 1998 Name change to Aalborg Industries as per 1st September 98 for all group companies 1999 Acquisition of Wiesloch (thermal fluid heating systems), The Netherlands 2000 Aalborg Industries acquired by Danish investors group headed by Axcel 2000 Acquisition of ATA Combustão Técnica, Brazil boilers from Mitsubishi, Japan Subsidiary Ciserv AB, Sweden, sold to Wärtsilä, Finland 2002 Subsidiary Aalborg Industries Inc., USA, sold to Daekyung Machinery & Engineering Co. Ltd., Korea

5 Aalborg Industries Global overview Office locations Aalborg Stockholm Rauma York Rotterdam Dalian Pusan Kobe Tokyo Qingdao Shanghai Houston Dubai Hong Kong Singapore Jakarta Petrópolis São Paulo

6 Jakarta Indonesia Petrópolis Brazil Qingdao China Aalborg Denmark

7 Industrialization of Boiler Manufacturing

8 KEDEL DAMP Damp Vand

9 Three pass smoke tube boiler Steam space Saturated steam Saturated water Steam outlet Pass 3 tube Pass 2 tube Flue gas to stack 10 bar 184 o C 400 o C 220 o C 1000 o C Burner Oil 2000 o C Internal Reversal chamber Combustion Air Feed water inlet Furnace

10 MISSION TM 3 Pass

11 Aalborg Industries Business areas Marine Boilers Heat Recovery Steam Generators Industrial Boilers Heat Exchangers Inert Gas Systems

12 Complete solutions Exhaust gas economisers Composite boilers Heat exchangers Coolers Condensers Cargo heaters Oil-fired boilers Inert Gas Systems

13 Agenda 1. Introduction to Aalborg Industries 2. Why Product Configuration? 3. The Standardisation Process 4. Challenges 5. Demonstration of Configuration Tool

14 Aalborg Industries Manufacturing Office locations Aalborg Stockholm Rauma Erie York Rotterdam Dalian Pusan Kobe Tokyo Qingdao Shanghai Houston Dubai Hong Kong Singapore Jakarta Petrópolis São Paulo

15 Competitiveness through Standardisation Quicker and more precise clarification with the customer Increased application of prefabrication (From unit production till mass-produced components) Increased automation of the order process Reduction of mistakes. Stronger purchasing power (Volume / stock purchase)

16 Improvement of Business Relationship with our Customers Improve the basis for shipyard s competitiveness through: Improved the communication Clarification of technical requirements early in project Fast documentation up-front Reduction of lead times Fast response on changes Fast installation and commissioning Less faults 3D models of boiler and other major components In future the Product Configurator allows the customer to design their boiler plant themselves

17 Agenda 1. Introduction to Aalborg Industries 2. Why Product Configuration? 3. The Standardisation Process 4. Challenges 5. Demonstration of Configuration Tool

18 Overlapping Boiler Products AQ12 AQ10/12W OS UNEX CHB OM AQ9 CHS CPH OL AQ18 D WPH AT8D AQ10/16W AQ16 GCS KH OC AR4-N AWN 3-Pass UNEX BH AR3C UNEX B AV14 WHR-GT Pioneer GE1 Pioneer GE2 AV10GE Pioneer AV10DE DE1 UNEX G AV8N AV6N EGE PT AO1 WIESLOCH EX TO1 WIESLOCH TF UNEX P AV9 AV4 AQ2 AV7 AQ7 UNEX H MICRO Boilers in Grey Italic has no sales record in 2001

19 Grouping of Products AQ12 AQ10/12W OS UNEX CHB AQ9 CHS OM CPH OL AQ18 D WPH AT8D AQ10/16W AQ16 GCS KH OC AR4-N AWN 3-Pass UNEX BH AR3C UNEX B AV14 WHR-GT UNEX G AV8N EGE AV6N PT TO1 WIESLOCH TF AV4 AV7 AQ2 AQ7 UNEX H AO1 UNEX P MICRO WIESLOCH EX AV9 Boilers in Grey Italic has no sales record in 2001

20 AWN AR4N AQ18 OL OS 3-Pass OL OM 2-Pass XS TFO XTF XW OC UNEX B UNEX BH AR3C AV4 AV7 AQ7 AQ2 UNEX H AV6N AV8N UNEX G PT EGE AV9 UNEX P AO1 WIESLOCH EX AQ16 GCS UNEX KH AQ10/16W OC TO1 WIESLOCH TF AQ12 UNEX CHB AQ10/12W OS CHS AQ9 CPH OM Standardisation into Product Families

21 Configuration of Boiler Plants (Complete Systems)

22 Consolidating Best Practice Predefined Concepts and well-defined Options Container ships Crude carriers Gas tankers Cruise ships Koncept # 9 Koncept # 7 Koncept # 2 Concept # 1 2 x MISSION OM 2 x MISSION 1 OL x MISSION XW 2 x MISSION 1 OL x MISSION 1 XW 2 x MISSION x Power Panel 1 OL x MISSION 1 XS x Power Panel 1 x MISSION 1 x Feed Water Pumps 1 XW x Power Panel 1 x Feed Water 1 x Pumps 1 x Power Panel Circulation Pump 1 x Feed Water 1 x Pumps Circulation 1 x Pump 1 x Feed Water Fuel Oil Unit 1 x Pumps Circulation 1 x Pump Fuel Oil Unit 1 x Circulation 1 x Pump Fuel Oil Unit 1 x Fuel Oil Unit Service Steam.. Oil Fired WHR Boiler Boiler (without.. Steam space) Feedwater Pump Unit Circulation Pump Bottom Tank

23 Intelligent Product Configuration Tool Customer Options Class Rules Engineering Experience Production Experience Product Configuration Tool Consistent and well-proven Solutions

24 Documentation and Drawings from the Product Configurator Price Calculation Documentation Configuration tool Drawings

25 Product Family Master Plan Heat and steam generating system Control system [1..2] Boiler NB: Attributes for "Heat and steam generating system" are specified on seperate sheet (as "Functional attributes"). Type [oilfired, gasfired, WHR, combi ] Relay PLC Microprocessor The preferred class of water and steam section depends on the required stam pressure and the required steamflow. In theory all the classes can be designer for the required pressure range and steam flow range but the plate scantlings will be increase dramatically. The typical relations are expressed in the following table Steam pressure [barg] Steam Flow [t/h] Orientation [Vertical, horizontal] Burner position [Top, Side] Sandbluss [none, SA2.5] Paint color [Red, Silver (heat resistant] [1, 3] Relay Panel 1,2 1,2 Boiler Control panel Motor starter center Maker [York electronic] Water & steam section Drum x x Space x x x Chamber x x [1] [1] Pressure part Boiler equipment 1,10 Motorstarters 1, 20 Motorstarters Service level [Essential, important] 0,1 Transformer Relationships between service level and transformer [0,1] [1] [1] [1] Burner system Controlsystem Auxilleries Water / steam system [1] Water level control [1] Forced circulation system 0, ,1 0,1 0,1 Cabinet seperator Start Stop Running indicator Auto/manuel Switch Auto/manuel Indicator Hour Counter Ground detection Ampmeter If the required service level is essential a transformer and a cabinet separator is mandatory Relationships between power and the ampmeter Use of Ampmeter is optional but if the power is greater than 11Kw a transformer is mandatory [1] Water treatment [1] Main steam system ,1 Switch Terminal Remote start/stop [0,1] Exhaust system Part-of model Kind-of model Rules and relations

26 Variability has a Cost! Component Maker [...,...,...] Variability Dimension [...,...,...] Auxilleries Variability [0, 1] Circulation pump unit Control system Variability Relay PLC Microprocessor

27 Configurable Boiler Plants supporting Market Demands Product Family Master Heat and steam generating system Market [1..2] Boiler NB: Attributes for "Heat and steam generating system" are specified on seperate sheet (as "Functional attributes"). Type [oilfired, gasfired, WHR, combi ] Orientation [Vertical, horizontal] Burner position [Top, Side] Sandbluss [none, SA2.5] Paint color [Red, Silver (heat resistant] Demands [1] [1] Pressure part Boiler equipment Match [0,1] [1] Burner system Controlsystem [1] Auxilleries Configurable Solutions [1] [1] Water / steam system Water level control [1] Forced circulation system Boiler Plants [1] [1] Water treatment Main steam system [0,1] Exhaust system

28 Sales and Order Execution Configuration tool ERP System Customer Has a need Makes Bill-of- Material Bill-of-Material is attached to the order in the ERP system Quote Drawing and/ or 3D model Configurator uses rules to select a product family and configure a valid solution ERP system containing AI items and operations (cutting, welding, etc.). Platform rules refer to AI items and operation Product platform rules (Predefined Standards) Item Catalogue Operation Catalogue

29 Agenda 1. Introduction to Aalborg Industries 2. Why Product Configuration? 3. The Standardisation Process 4. Challenges 5. Demonstration of Configuration Tool

30 Challenges Global Similarities vs. Local Differences Market requirements (e.g. DIN/JIS flanges) Material standards (e.g. EN/GB/NK standards) The configurable product platform is not complete To handle partly configurable solutions The order port folio - long horizon Repeat orders

31 Challenges (Cont.) Configured Boiler Plant Order Execution Etc. Order Execution - AAL Order Execution - UKB Order Execution - PUS Sales Delivered Boiler Plants AAL JKT TAO RIO Production Sites Suppliers

32 Sales and Order Execution Reference Model Customer Sales & Sales Support Orderprocessing Production & Materal Planning Production Shipment & Commissioning After Sales & Maintenance Scope of Delivery Defined Sales & Order Execution 100 % Engineering Need Concept Sale Customer Interest Phase Sales Phase Order Processing Phase Order Manufacturing and Delivery Phase Maintenance Phase Customer Order Recieved Delivery Accepted by Customer

33 Sales and Order Execution Reference Model Customer Sales & Sales Support Orderprocessing Production & Material Planning Production Shipment & Commissioning After Sales & Maintenance Scope of Delivery Defined Sales & Order Execution 100 % Engineering Customer Interest Phase Sales Phase Order Processing Phase Order Manufacturing and Delivery Phase Maintenance Phase Customer Order Recieved Delivery Accepted by Customer

34 Sales and Order Execution Reference Model Customer Sales & Sales Support Orderprocessing Production & Material Planning Production Shipment & Commissioning After Sales & Maintenance Scope of Delivery Defined Sales & Order Execution 100 % Preferred Engineering Customer Interest Phase Sales Phase Order Processing Phase Order Manufacturing and Delivery Phase Maintenance Phase Customer Order Recieved Delivery Accepted by Customer

35 Sales and Order Execution Reference Model Customer Sales & Sales Support Orderprocessing Production & Material Planning Production Shipment & Commissioning After Sales & Maintenance Scope of Delivery Defined Sales & Order Execution 100 % Optimal Customer Interest Phase Sales Phase Order Processing Phase Order Manufacturing and Delivery Phase Maintenance Phase Customer Order Received Delivery Accepted by Customer

36 Sales and Order Execution Reference Model Customer Sales & Sales Support Orderprocessing Production & Material Planning Production Shipment & Commissioning After Sales & Maintenance Scope of Delivery Defined Sales & Order Execution 100 % Web Sales Customer Interest Phase Sales Phase Order Processing Phase Order Manufacturing and Delivery Phase Maintenance Phase Customer Order Recieved Delivery Accepted by Customer

37 Challenges (Cont.) Shipyard s Value Chain Initial Design Purchasing Project Design Boiler Installation Boiler Plant Specification Scope of Supply Boiler Performance P&I Diagrams / List of Parts Installation Manual 3D Boiler Model Arrangement Drawings Instructions & Datasheets As-build Documentation Maintenance Manual

38 Agenda 1. Introduction to Aalborg Industries 2. Why Product Configuration? 3. The Standardisation Process 4. Challenges 5. Demonstration of Configuration Tool

39 Sales and Order Execution of Configured Solutions Request Create/Update Request Non-Configurable Add-On Configure Product E.g. - OS - Special Pump Unit Customer Documents to Customer Calculate Price TeSAI Engineering Price Calculation Create Documentation Documents for Order Execution Production Sites

40 Demonstration of the Product Configuration System

41 Some Experiences Economical Initial cost (investment) Increased maintenance cost Long term saving Organisation and workflow Changed workflow Changed work contents Changed skill requirements Changed organisation Non-configurable solutions Difficult and complex Time consuming Availability of skill

42 Thank you for your attention!