• International Journal of Naval Architecture and Ocean Engineering
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• v.12 no.1
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• pp.20-37
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• 2020

In this paper, we propose a simulation method based on backward simulation and process-oriented simulation to take into account the characteristics of shipbuilding production, which is an order-based industry with a job shop production environment. The shipyard production planning process was investigated to analyze the detailed process, variables and constraints of mid-term production planning. Backward and process-centric simulation methods were applied to the mid-term production planning process and an improved planning process, which considers the shipbuilding characteristics, was proposed. Based on the problem defined by applying backward process-centric simulation, a system which can conduct Discrete Event Simulation (DES) was developed. The developed mid-term planning system can be linked with the existing shipyard Advanced Planning System (APS). Verification of the system was performed with the actual shipyard mid-term production data for the four ships corresponding to a one-year period.

• Journal of the Society of Naval Architects of Korea
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• v.53 no.5
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• pp.353-361
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• 2016

Recently, the small shipyard companies have difficulties that causes by depression of shipbuilding industry. The small shipyard companies need some strategies to overcome the slump in shipbuilding industry field. In this paper, we conduct the survey for present condition diagnosis of small shipyard companies, and analyze the production process based on Information Strategy Planning(ISP) method. When analyze based on ISP, we apply IDEF0 and LOVC technique to analyze the production process of small shipyard companies. Also we conduct the gap analysis between the analyzed present condition and the requirements of improvement. Therefore, the most important result of the analysis is to establish a system for enterprise planning and management, which customized for small shipyard companies, with satisfying economic feasibility and usability.

• International Journal of Naval Architecture and Ocean Engineering
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• v.10 no.6
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• pp.741-761
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• 2018

A shipyard is an Engineer To Order (ETO) company that designs and manufactures new products when orders are placed. Various tasks are concurrently performed, thereby making process management considerably important. It is particularly important to plan and control production activities because production constitutes the largest part of the overall process. Therefore, this study focuses on the development of a production planning system based on an Advanced Planning System (APS). An APS is an integrated planning system that targets supply chain processes in accordance with the principles of hierarchical planning. In this study, a Supply Chain Planning Matrix (SCP-Matrix), which is used as a guideline for APS development, is designed through analysis of shipyard cases. Then, we define the process in detail, starting from long-term production plan as the initial application, and design and implement a long-term production planning system using a component-based development.

• Journal of the Society of Naval Architects of Korea
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• v.45 no.5
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• pp.547-553
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• 2008

Multi Progress Planning System problem in a multi-stage manufacturing system have a complexity and peculiarity different from other kinds of production system. World leading company has invested much cost and effort into a Real-Time Planning System and intelligent manufacturing field to obtain their own competitiveness. Especially Real-Time Planning System for ship production process as a part of intelligence for a shipyard. Real-Time Planning System, simulation based system, or virtual manufacturing system is an approach to achieve a such goal. It is expected that the Real-Time Planning System will contribute to the improvement of the productivity in working process at a shipyard. Also, This Real-Time Planning System will optimize the entire shipbuilding process in a multi progress planning environment for the delivery.

• International Journal of CAD/CAM
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• v.6 no.1
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• pp.19-27
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• 2006

To survive in the current shipbuilding industry it is of vital importance for shipyards to achieve an optimal utilization of resources, make an achievable planning and ensure that this planning is kept. Possible problems should be eliminated before production starts and if unexpected disturbances occur in the actual production the right measures should be taken. Due to the dynamic nature of the production process, the continuous variation in products and the complexity of both, all this can hardly be achieved with conventional static planning and analysis systems. Simulation provides a solution here, since this enables the modelling and evaluation of the dynamic relations between product and production process. After a global introduction to production simulation in general and the application of simulation at the Flensburger shipyard, this paper presents a tool that has been developed to simulate the various complex assembly processes taking place at shipyards. Subsequently the simulation model for the subassembly production at Flensburger, in which this tool is applied, will be discussed.

• International Journal of Naval Architecture and Ocean Engineering
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• v.13 no.1
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• pp.405-430
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• 2021

Production planning is a key part of production management of manufacturing enterprises. Since computerization began, modern production planning has been developed starting with Material Requirement Planning (MRP), and today Enterprise Resource Planning (ERP), Advanced Planning and Scheduling (APS), Supply Chain Management (SCM) has been spreading and advanced. However, in the shipbuilding field, rather than applying these general-purpose production planning methodologies, in most cases, each shipyard has developed its own production planning system. This is because the applications of general-purpose production planning methods are limited due to the order-taking industry such as shipbuilding with highly complicated construction process consisting of millions of parts per ship. This study introduces the design and development of the production planning system reflecting the production environment of heavy shipyards in Korea. Since Korean shipyards such as Hyundai, Daewoo and Samsung build more than 10 ships per year (50-70 ships in the case of large shipyards), a planning system for the mixed production with complex construction processes is required. This study draws requirements using PI/BPR (process innovation and business process reengineering) methodology to develop a production planning system for shipyards that simultaneously build several ships. Then, CBD software development methodology was applied for the design and implementation of planning system with drawn requirements. It is expected that the systematic development procedure as well as the requirements and functional elements for the development of the shipyard production planning system introduced in this study will be able to present important guidelines in the related research field of shipbuilding management.

• Korean Journal of Computational Design and Engineering
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• v.13 no.1
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• pp.18-26
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• 2008

Shipbuilding industries have been struggling to reduce production time and cost of their products in many aspects. Manufacturing systems have been changed, new production lines and robots have been installed, and new planning and scheduling systems have been adopted in order to achieve shorter time-to-market and higher productivity. Simulation based manufacturing, digital manufacturing, or virtual manufacturing simulation, whatever the name means, is an approach to achieve such a goal. In order to improve productivity in a shipbuilding process at a shipyard, a digital shipyard development has been driven. This paper proposed how to implement the digital shipyard, what to do with it, and what to obtain from it. This digital shipyard will help simulate and optimize the entire shipbuilding life cycle with its virtual environment through shipbuilding process from the initial development stage to the launch.

• Korean Journal of Computational Design and Engineering
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• v.17 no.2
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• pp.111-122
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• 2012

Capacity planning plays an important role not only for master production plan but also for facility or layout design in shipbuilding. Product work breakdown structure, attributes of production resources, and production method or process data are associated in order to make the discrete event simulation model of shipyard layout plan. The production amount of each process and the process time is assumed to be stochastic. Based on the stochastic discrete event simulation model, the production capacity of each facility in shipyard is estimated. The stochastic model of product arrival time, process time and transferring time is introduced for each process. Also, the production capacity is estimated for the assumed master production schedule.

• International Journal of Naval Architecture and Ocean Engineering
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• v.6 no.2
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• pp.471-483
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• 2014

Since 2009 of global financial crisis, shipbuilding industry has undergone hard times seriously. After such a long depression, the latest global shipping market index shows that the economic recovery of global shipbuilding market is underway. Especially, nations with enormous resources are going to increase their productivity or expanding their shipyards to accommodate a large amount of orders expected in the near future. However, few commercial projects have been carried out for the practical shipyard layout designs even though those can be good commercial opportunities for shipbuilding engineers. Shipbuilding starts with a shipyard construction with a large scale investment initially. Shipyard design and the equipment layout problem, which is directly linked to the productivity of ship production, is an important issue in the production planning of mass production of ships. In many cases, shipbuilding yard design has relied on the experience of the internal engineer, resulting in sporadic and poorly organized processes. Consequently, economic losses and the trial and error involved in such a design process are inevitable problems. The starting point of shipyard construction is to design a shipyard layout. Four kinds of engineering parts required for the shipyard layout design and construction. Those are civil engineering, building engineering, utility engineering and production layout engineering. Among these parts, production layout engineering is most important because its result is used as a foundation of the other engineering parts, and also, determines the shipyard capacity in the shipyard lifecycle. In this paper, the background of shipbuilding industry is explained in terms of engineering works for the recognition of the macro trend. Nextly, preliminary design methods and related case study is introduced briefly by referencing the previous research. Lastly, the designed work of layout design is validated using the computer simulation technology.

• International Journal of Naval Architecture and Ocean Engineering
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• v.8 no.5
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• pp.496-510
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• 2016

Simulation technology is a type of shipbuilding product lifecycle management solution used to support production planning or decision-making. Normally, most shipbuilding processes are consisted of job shop production, and the modeling and simulation require professional skills and experience on shipbuilding. For these reasons, many shipbuilding companies have difficulties adapting simulation systems, regardless of the necessity for the technology. In this paper, the data model for shipyard production simulation model generation was defined by analyzing the iterative simulation modeling procedure. The shipyard production simulation data model defined in this study contains the information necessary for the conventional simulation modeling procedure and can serve as a basis for simulation model generation. The efficacy of the developed system was validated by applying it to the simulation model generation of the panel block production line. By implementing the initial simulation model generation process, which was performed in the past with a simulation modeler, the proposed system substantially reduced the modeling time. In addition, by reducing the difficulties posed by different modeler-dependent generation methods, the proposed system makes the standardization of the simulation model quality possible.