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1University of Rostock | Naval Architecture and Ocean Engineering February 2012University of Rostock | Naval Architecture and Marine Engineering

Title: “Modeling & Simulation of a Production line(Panle line) in Shipbuilding Industry using Tecnomatix Plant Simulation 9.0”

Author: Yohannes Tekle Muhabie

Rostock ,Germany February 7, 2012

2University of Rostock | Naval Architecture and Ocean Engineering February 2012

Presentation Outline

► Introduction

► Objective

► Research Methodology

► Flow Chart

► Data Collection & Synthesis

► Model Development

► Scenario Analysis

► Interface with MS Office

► Conclusion

3University of Rostock | Naval Architecture and Ocean Engineering February 2012

Introduction/Overview of ship building Industry

Ship Yard

Ship Owner/Operator

Model Testing

Suppliers Engineering offices

Classification society

•One of a kind •Multiple systems •No percentage completion

Characterized by

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Objective of the thesis

► General Objective ► Analyze and optimize the panel line

► Specific Objectives ► Data identification and synthesis

► Model and simulate the panel line

► Bottleneck identification

► Investigating the effect of new work station

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Research Methodology

Literature Review Books, Journals, Articles, Manuals, people etc.

Data Collection Spread sheet and drawings

Analysis and Synthesis Converting the data in to suitable format

Model Development Representation

Verification & Validation Checking the developed model against some checklists

Scenario Analysis Developing alternative solutions

Conclusion Summarizing the results

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Steel Structure Production Sequence

Ref. Ship production Lecture note ( Permission from Dr. Ulrich Kothe)

Panel Line

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Flow chart

Start

is data suitable ?

End

Sankey Diagram

Modeling

Verify and Validate

Scenario Analysis

Documentation

Date PreparationYes

No

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Date Collection and Synthesis

► Data Available ► Spread sheet from P and S ship yard (Container Ship)

► Drawing (Tanker Ship )

6 plates 5 welds

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9University of Rostock | Naval Architecture and Ocean Engineering February 2012

Sankey Diagram, Cycle and Takt time (Container)

0

50

100

150

200

250

Cycle timeminute

Takt timeminute

17%

12%

13%

Input

S1

S2 S3

S4 S5 S6 Output

49%

39%

19%

61%

7%

32%

61%

S1 S2 S3 S4 S5 S6

-48.1

12.7 -14.9 -5.9

76.6

4039 sheets/yr

Bottleneck

82 67.1

10University of Rostock | Naval Architecture and Ocean Engineering February 2012

Model Development (Tecnomatix Plant Simulation 9.0 )

Assumption: 99% availability MTTR : 2 minutes

3996 sheets/yr

•It is a discrete event simulation (DES) program

Bottleneck

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Verification and Validation of the Model

► Does it provide utilization of each work station?

► Helps in decision making process (PPC)?

► Are the results easy to understand and interpret ?

► Does it indicate the influence of each workstation?

► Effect of adding a new work station ?

The following check lists have been taken into account

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Improving production rate (Experimental Manager)

3900

4000

4100

4200

4300

4400

4500

4600

50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82

Nu

mb

er o

f sh

eets

Cycle time (Minute per sheet)

OutPut

OutPut

=(4451-3996)/3996*100%

=11.4% improvement

4451 sheets/yr

Points for improvement:

• Additional manpower hiring •Improving the technology •Future demand

Profile welding

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13University of Rostock | Naval Architecture and Ocean Engineering February 2012

Profile welding and Completion Combined

Experiment

Profile welding

Minute

Completion

Minute

Output

Sheets

16 50 65 5041

40 51 65 5041

64 52 65 5041

88 53 65 5041

112 54 65 5041

136 55 65 5041

160 56 65 5041

184 57 65 5041

208 58 65 5041

5041

=(5041-3996)/3996*100%

=26.2% improvement

14University of Rostock | Naval Architecture and Ocean Engineering February 2012

Adding new work station (PVPs station)

Purpose: Analyzing the effect of new work station

Parameters:

�One stiffened panel comprises 2.25 sheets

�Ten points for proper placement of PVPs (0.5 minute each)

�Robot welding

�Speed , V=0.0083 m/s

�Length, L=2.8 m

Single run, time=L/t= 5.62 minutes

Considering 4 runs to entirely weld the PVPs = 4*5.62=22.5 minutes

Total time for a single PVPs operation = 28.5 minutes

PVPs

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Cycle time (PVPs ) Station

0

20

40

60

80

100

120

140

160

0 1 2 3 4 5 6 7 8 9 10 11 12 13Cyc

le t

ime

(Min

ute

per

sh

eet)

Number of PVPs per Panel

Cycle time (PVPs)

Cycle time

3994 sheets/yrNo significant effect

3695 sheets/yr

Decline by 7.5 %

PVPs=6

PVPs=7

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Genetic Algorithm (GA)

GA helps to find out an optimal solution based on a stochastic

approach and it starts with an initial random solution set [20].

Objective: Maximize Production rate

Subject to :

30<=X1<=54.4 / Profile setting station/

50<=X2<=82 /Profile welding/

50<=X3<=73 /Completion/

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17University of Rostock | Naval Architecture and Ocean Engineering February 2012

Genetic Algorithm (GA)

X1=33, X2=50, X3=506497 sheets

Tanker Ship

X1=40, X2=40, 8120 sheets

Container Ship

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Integrating Ms Access and Excel in the process

Input Data

MS-Access

Process

Plant Simulation

Software

Output

MS-Excel

Connection (ODBC)

Accessing the data

from the Database

Exporting the

resultsCopying and saving the

data in the simulation

table (Operation sheet)

Passing the data to the

objects (machines) in the

station

Performing simulation and

saving the results in to a

table

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Data consistence

Due attention has been given for data consistence. For example :

Description MS Access Simulation

Processing Time Integer(Second) Time

Processing time

ConstantNormal Distribution

Mean, Stream and standard deviation

Mean

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Conclusion

�It facilitates the decision making process

�Profile welding is the station where due attention has to be given

�It is suitable for new work station design

�Max number of PVPs are 6 and 4 for Container & Tanker

respectively

Future work :

�Cost benefit analysis has to be incorporated

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21University of Rostock | Naval Architecture and Ocean Engineering February 2012