Overview of Productivity
Improvement Strategies Using
Simulation in Shipbuilding
SUGANEESWARAN A/L MOHANAKRISHANAN 56211218003
IFFAH MUNIRAH BINTI MOHD SAIFUL ASRI APPARAU 56211218013
INTRODUCTION
• is to study the present improvement strategies using simulation employed by the shipyard for
new building and repair works.
• to investigate a strategy to advance production management specialised for the shipbuilding
based on current information technologies (IT) and simulation-based management methods.
• identify and specify the strategies using simulation in shipbuilding.
AIM OF STUDY
• In this research, the scope of study will be to identify the terms and definitions related to ship
production process.
• Besides, the researchers also want to interpret the concepts of ship production system design
and main hardware elements of shipyards.
RESEARCH REVIEW
The estimation of a good shipbuilding is related to the project criteria quality, time, and
costs.
• Mostly, optimum solutions for all criteria cannot be found. For example, an exceeding quality
leads to higher costs as normal.
• Thus, a well-developed project organization focusing on a steady work flow and efficient
capacity utilization is needed for the realization of a construction project successfully.
• Therefore, high level of competence and extensive project experience are imperative.
Simulation of production is a very useful method regarding benefits possibilities in production
process and subsequently cost reduction.
• To achieve an optimum integration design vs. production, it is necessary to model not only the
ship but also the facilities if the shipyard and combine them into a single simulation model.
• Best results can be obtained when this model is linked with other optimizations systems.
• The simulation helps to find the suitable workshop layout and assembly sequence according the
ship’s construction strategy.
Shipbuilding simulation method is useful
• The shipbuilding simulation method can be useful for evaluating, determining and communicate
planning of the production, enabling a dynamic and transparent production review.
• The technique will enable the project to identify the vessels or the production assessment by
various vessel types.
PRODUCTIVITY IMPROVEMENT
STRATEGIES USING SIMULATION
• The strategies proposed use simulation that enable efficient and reasonable production planning
and production management.
• The simulation definition used here is based on the PDS (Plan Do-See) Cycle (Fig. 1).
• The principle facilitates numerous topics that occur at the actual shipbuilding company such as
workload balancing, logistic optimization, erection process optimization, material ordering,
material management, optimization of each production process, and integration.
FIGURE 1 SIMULATION APPROACH
DETAIL STRATEGIES FOR THE SIMULATION
BASED PRODUCTION MANAGEMENT
The strategies described are classified into two parts:
• foundation strategies
• application strategies
Foundation strategies are designed for and relevant to the shipbuilding industry, whereas the
application strategies are compatible with general and practical target design productions.
FOUNDATION STRATEGIES
1) Data standardization
• Comprehensive knowledge of the work processes within each departments (design, production,
planning, logistics, and material) providing information and specification which required for
data standardization.
• By these attempts of standardization, the data are rearranged within the ship production point
of view.
FIGURE 2 CASE STUDY OF A
STANDARD PROCESSING TIME
2)Simulation technique
• The basis of the simulation strategy makes intensive use of computer simulation.
• A simulation method is considered necessary in the shipbuilding domain for critical decision
making.
• Furthermore, there is also variety in production types and in yard status.
• A shipbuilding simulation method differs significantly from traditional methods based on
knowledge of industrial engineering. Extensive simulation strategies are required to consider
variation in planning conditions, production time and order of production
FIGURE 3 DIGITAL SHIPBUILDING
3) Optimization techniques
• Researches find that several attempts are made to improve the shipbuilding.
• There have been drawbacks to such attempts mostly due to various assumptions.
• These limitations are unavoidable because the production system for shipbuilding is highly
complex.
• The optimization object needs to be defined at early stage to secure all the information needed for
each target process.
• Table 1 shows the methods of optimization and the targets concerned.
APPLICATION STRATEGIES
1)Technique for the simulation based production planning system
• The aim of the production planning system is to enable the development of balanced and
executable planning data.
• The system is based on the use of standardized production data and computer simulation.
• A system can transform the planning activities from those with seemingly infinite capacity to
finite capacity.
• Simulation-based production planning in shipbuilding also supports multi-disciplinary decision
making a good prediction.
FIGURE 4 A SIMULATION BASED
PLANNING SYSTEM
2) Technique for the simulation based process planning system
• The most important aspect of shipbuilding process planning is to decide the items to be produce
during production.
• Decisions on a feasible work order sequence and a feasible process planning is important for ship
production.
• Accordingly, simulation-based process planning should support multi-disciplinary decision
making in shipbuilding strategy.
• Shipbuilding planner could optimize a process planning with the simulation function.
FIGURE 4. PROCESS PLANNING BASED
ON THE SIMULATION
DISCUSSION
• It is important to improve the production management strategies in shipbuilding industry in
order to increase the total production and quality. It also help to reduce rework and unnecessary
cost. The initiative took is with a bit of combination with nowadays technologies and
machineries. This alternative is benefited in many aspects.
• With used of technologies and machineries, total of manpower needed in industry can be
reduce. Hence, wages cost also can be reduced. The cost needed is just for machine
maintenance and upgrading technologies or systems. This also can reduce the risk of human
injuries in site which also can cut the expenses on workers welfare fund.
• Using simulation in shipbuilding industry also may give an accurate product with high quality
compare by using manual manpowers. Launching and inspection by using simulation will
results in accurate report and can reduce work and time to produce a 98% product. Hence, this
will increase the quality and productivity of the industry.
• The duration for production also can be decreased machine can be operated 24 hours with low
flaws compare to human. This can increase the productivity of industry. More production with
low cost and in a short time. It will give a big profit to the industry.
• However, this improvement may cause many people to lost their job and source of incomes.
This will result in the increment of rate of unemployment in world. So, this improvement may
give some pros and cons in life.
CONCLUSION
• Improvement in an industry is needed regularly in order to keep improving the productivity of
management and production of industry. With the used of simulation in shipbuilding industry, it
can enhanced the production and improving the production system in the industry. It also may
result in a great profit, quality and positivity to the industry. It also can work along with the
global trend that move and improve toward modern technologies and systems.
