Challenge: On-Time Delivery of Ships
Delivering on time is not an option; it's a must for shipyards to stay profitable and remain competitive.
Any delay in ship delivery can lead to penalties and affect the already low margin of the shipyard. New production technologies are required to deliver faster and cheaper while maintaining quality. This transition is even more present in the biggest Asian shipyards, illustrating the significant consolidation within the shipbuilding industry over the last 15 years.
The top 10 shipyard groups account for 71% of the global order book
Source: Splash 247.com
Following years of decline in new ship orders, the global shipyard landscape is expanding amid unprecedentedly large order books. Influenced by the knowledge that a substantial portion of existing fleets must be replaced to comply with emerging green regulations, shipbuilders are now looking for digital manufacturing solutions that drive automation in the shop floor to increase efficiencies across all shipyard departments.
As it stands, some of the world's largest shipbuilders are affected by late delivery penalties and higher manufacturing costs.
Hyundai Heavy Industries Co. blamed the loss on penalties worth 20 billion won ($14,5M) for the late delivery of a special-purpose ship and rising thick steel plate prices.
Source: The Korean Herald
Embracing the concept of a smart shipyard has become imperative for industry players looking to stay ahead of the competition. A smart shipyard leverages advanced technologies and data driven solutions to optimize all aspects of shipbuilding:
Digital manufacturing enables shipyards to validate critical production processes and potential clashes that exist in production. For example, commercial shipyards in Asia benefit from a 60% reduction in errors during the execution phase by leveraging Dassault Systèmes' digital manufacturing solutions.
A reliable advance planning and scheduling (APS) solution not only determines the assembly and erection of blocks but also the work schedule and spatial batch planning. The APS provides important information to support the management's decision-making process and drive the shipyard strategy.
The quality of production planning determines the productivity of a shipyard. Using the right planning solution will enable shipyards to optimize ship delivery. Based on Dassault Systèmes' customer achievements, some of the largest shipyards experienced a 3% reduction in production buffer. This improvement helped the shipyards increase shipyard capacity, resulting in the ability to produce additional blocks of up to one ship annually for large shipyards. Additionally, planning efficiency increased by 30%.
Dassault Systèmes' DELMIA manufacturing operations management (MOM) solution is more than a manufacturing execution system (MES). The MOM footprint is across all operations within manufacturing – from production to quality and warehouse – and even in the supply chain, maintenance and labor management.
Through MOM, global shipyards have better control of their shipyard operations. Feeding real-time information into the planning and scheduling system allows shipyards to anticipate potential production issues.
Real-time feedback can significantly increase traceability, providing insights into material status and a clear visibility of what is happening in production. Once the customer business process is defined in the system, reusing it in multiple workshops or shipyards is critical for multi-site shipyards. Thus, the same way of working can be applied to all shipyards worldwide. The main benefit of this approach is the harmonization of manufacturing processes using a core model approach – making deployment fast, manageable and reliable.
Excel With the Build for Sea Industry Solution Experience
Dassault Systèmes' DELMIA Shipyard Manufacturing Execution and Monitoring solution stands out for its well-known customization capabilities tailored for large shipyards dealing with:
- Complex constraints
- Optimization challenges
- High production volumes
- Supply chain intricacies
The solution allows manufacturers to use data-driven KPIs to measure productivity, material flow and cycle times – enhancing the entire production system with real-time updates.
Shipyard Manufacturing
Execution and Monitoring
Shipyard Production
Scheduling and Execution
Shipyards and suppliers with specific workshop requirements can benefit from Dassault Systèmes' DELMIA planning and scheduling solution. The solution allows shipyards and suppliers to efficiently define, optimize and manage shipyard resources and production plans.
Ship Manufacturing Challenges
Today's shipyards face challenges on many fronts and must transform their process to stay competitive.
Challenge: Optimizing Shipyard Infrastructure
Optimize shipyard infrastructure capacity to improve productivity and margin.
Challenge: Workforce Management
The shipbuilding industry requires an experienced workforce to undertake highly complex projects like submarines or commercial vessels.
Smart Shipyards
Manage, control and optimize shipbuilding processes – from engineering to manufacturing – and meet customer demands for time, cost and quality.