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자원제약을 고려한 조선 대조립 공정의 통합 프로세스 기반 모델 설계

Design of Integrated Process-Based Model for Large Assembly Blocks Considering Resource Constraints in Shipbuilding

  • 투고 : 2019.02.01
  • 심사 : 2019.06.17
  • 발행 : 2019.06.30

초록

조선업은 한정된 자원을 사용하는 single-product production방식이며, 리소스를 효율적으로 관리하여 선박 공정의 생산성을 극대화 시킬 수 있는 생산관리기술이 중요하다. 때문에 많은 조선사에서는 모델링 및 시뮬레이션을 적용함으로써 현장 내 다양한 제약 조건이 고려된 선박 생산계획 및 공정에 대한 연구를 수행하고 있다. 하지만 기존 연구들은 갑작스런 일정 및 공정변경 시 정확한 생산계획을 제공하기 어려우며, 블록을 생산하는 각 공정 간의 상호연관성 파악이 어렵다. 뿐만 아니라, 블록의 세부 공정 및 일량을 고려하지 못하였기 때문에 생산계획과 현장계획에 많은 차이가 발생한다. 본 연구에서는 조선 내업공정 내 스케줄 된 전체 블록의 공정작업 순서 및 설계정보, 그리고 자원 제약을 고려하는 모델링 방법인 통합 프로세스 기반 모델 설계 방법을 제시한다. 통합 프로세스 기반 모델을 통해 사용자는 내업공정 내 블록 간의 조립관계, 정반정보 및 조립공정의 선후관계 파악이 용이하다. 또한 조선 내업공정에서 공유하는 리소스의 일량을 고려하여 부하 평준화를 진행하기 때문에 별도의 시뮬레이션 및 리소스의 모델링 절차 없이 리소스 효율을 최대화 할 수 있는 전체 생산계획을 얻을 수 있다.

Because shipbuilding is single-product production with limited resources, production management technology is essential to manage the resources effectively and maximize the productivity of ship-process. Therefore, many shipbuilding companies are conducting research on ship production plan and process considering various constraints in the field by applying modeling and simulation. However, it is difficult to provide accurate production plan on sudden schedule and process changes, and to understand the interconnectivity between the processes that produce blocks in existing research. In addition, there are many differences between the production planning and field planning because detailed processes and quantity of blocks can not be considered. In this research, we propose the integrated process-based modeling method considering process-operation sequences, BOM(Bill of materials) and resource constraints of all the scheduled blocks in the indoor system. Through the integrated process-based model, it is easy for the user to grasp the assembly relationship, workspace and preliminary relationship of assembly process between the blocks in indoor system. Also, it is possible to obtain the overall production plan that maximizes resource efficiency without the separate simulation and resource modeling procedures because resource balancing that considers the amount of resource quantity shared in the indoor system is carried out.

키워드

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Fig. 1. Production process of the BLKs

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Fig. 2. Workflow modeling patterns

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Fig. 3. Timed Petri-net of work flow primitives

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Fig. 4. Concept of the Integrated Process-based Modeling

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Fig. 5. Bill of materials(BOM) of BLK TT1

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Fig. 6. Structure of the unit models

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Fig. 7. Conversion BOM into Workflow

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Fig. 8. Procedure of integrated process-based modeling

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Fig. 9. Flow chart of resource balancing

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Fig. 10. Calculation of resource allowance (BLK TT1)

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Fig. 11. Result of resource balancing (BLK TT1)

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Fig. 12. User interface for integrated process-based modeling

Table 1. Detailed description of the production process for the shipbuilding

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Table 2. Quantity information by resource types

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Table 3. Activity data of the BLK TT1

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Table 4. Results of resource balancing

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