IT for 21C Shipbuilding Industry - CAD/CAM & IT Trends in Shipbuilding -

1. 2001 Korea-Japan CAD/CAM Workshop IT for 21C Shipbuilding Industry- CAD/CAM & IT Trends in Shipbuilding - July 12, 2001 DAEWOO SHIPBUILDING & MARINE ENGINEERING CO., LTD

2. DSME Okpo Shipyard Yard Facilities • Site Area : 4,206,000 ㎡ • Covered Shop : 351,000 ㎡ • Outfitting Quays : 3,198 m • Docks : 2 Dry Docks(530X131X900T, • 350X81X450T) & • 3 Floating Docks Annual Production Capacity Commercial Ships 35 ~ 45 vessels Offshore Structures 2 ~ 4 projects Plants / Steel Struct. 25 ~ 30 plants Special Ships 1 submarine & 4 frigates - Number of Employees : 11,000

3. Major Products of DSME (1) - Commercial Ships COT (Crude Oil Tanker), VLCC ROPAX(RORO Passenger Ship) LNGC (LNG Carrier) RORO (Vehicle Carrier) Container Carrier

4. Major Products of DSME (2) - Offshores/Plants/Special Ships Plant (Gas Compression Platform) Drilling Rig, Semi-submersible FPSO (Floating Production Storage and Offloading) Frigate Submarine

5. Today of Korean Shipbuilding Industry • World widely No.1 in Market Share : 45% (2000) • Very Competitive in Cost & Productivity and Reasonably in Quality & Tech. • Flexible Technology & Design Capability based on Large Engineering Manpower Resource • Rapid Increase in Productivity by Implementing CAD/CAM & Other IT for last 10 Years but Currently Slow Down • Transition from Conventional Commercial Ships to High-Value Ships & Offshores - LNG Carriers - Super-Size Container Carrier - High Speed Ships - Passenger Ships - FPSO - Rig / SPAR / TLP & Other Offshores

6. IT for Shipbuilding Industry • IT is the key technology to maintain the shipbuilding business competitive. • “ a key tool for the competitiveness” - T. Koyama • “ a weapon, providing competition advantage” - A. Dallas • Innovation of information/process flow and data management is essential • for the competitiveness of 21C shipbuilding business. Shipyards • Product Model & Parametric Based Advanced CAD • Product Data Management & DBMS • Integration of CAD/CAM & Production Automation : Shipbuilding CIM • Information Share & Exchange : Ship CALS, Virtual Shipyard, WEB • CAD/System Vendor • Suppliers • Class, Government/Navy

7. Change of Shipbuilding Business Environment • Ship Owner’s Requirement • low cost but high performance & quality • faster, safer and better capacity • Mostly New Designs for each Order with Short Construction Period • concurrent and collaborative design & manufacturing • speed game, importance of time & schedule management • More Accurate & High Quality Information/Data Needed • increased design & engineering information • more and more details, multiple cycles of design spiral • Solution • Integration of information using IT for : • Increasing the Accuracy and on-Timing of Planning • Engineering for Production • Integration of CAD(Hull & Outfitting)/CAE/CAM/Production

8. Barriers in Shipbuilding IT to Be Overcome- Characteristics of Shipbuilding Practice • Mostly New Design for Each Order (Tailor-Made) • 15 - 20 New Design Developments per Year • Management of about 10 Different Products at the Same Time (Product-Mix) • Fabrication of Large Assemblies & Heavy Machineries • Uncountable Design & Production Processes, Steps and Activities • Large Number of Manpower, Organizations and Systems • Number of Parts : Size of Data or Objects • 105 (Ships) - 106 (FPSO, LNG, Plant) for each Product • [cf] Automobile : 20,000 - Airplane : 105 - 106 • Short Period of Design & Engineering for a New Product • 8-9 Months for each Ship • Concurrent Information Generation and Changes and Several Design Spirals within a Given Short Period. Needs for Management of Huge Size Data • Small Size of Shipbuilding IT Market • 3,500 CAD Seats(Korea), Less Than 20,000 CAD Seats(Worldwide) • Others : Large Scale & Complicated System Solutions (Integration & Interface), Complex Geometric Shape of Ships (Limited Space)

9. Ship Models : Hull-Form & Compartment Surface Models

10. Ship Models : Hull Structures Aft - Body Fore - Body

11. Ship Models : Outfitting(Seat/Pipe/Traffic/Handrail) Models 모델 Engine Room Deck

12. Key Technologies & Infra for Shipbuilding IT • Infra / Resources • Human Factor (Attitude & Under- • standing to New Tech. & Culture) • Standardization • BPR • Software Performance • Network Performance • Hardware Capability • Core Software Technologies • Parametric CAD • WEB • GUI • DBMS • PDM • OOP • Feature Based Modeling • Information Modeling • Visualization, VR • Distributed Object Computing • Data Exchange : STEP, IGES...

13. As below + Simulation Based Engineering Supplier Integration (B2B) Through Life Information Mgt Cost Management Benefit Network Capacity Wall Digital Prototype Engineering Data Management Concurrent Engineering Shared Data Environment Power Wall 2D Draughting Non Integrated Systems IT Development Trends in Shipbuilding * [PTC Data] Intelligent Product Model Advanced Visualization(VR) Engineering Data Management BoM to MRPII Concurrent Engineering World Class Shipyards Full 3D Model Visualization Point to Point Integration Functional Organisation Leading European, Asian and most US Shipyards Mainly 2D, Some 3D Non Integrated Systems Some European, Asian and US Shipyards

14. Worldwide IT Projects in Shipbuilding MARITIME ESPRIT MARVEL EMSA Etc. NSRP MARITECH COMPASS MariSTEP Etc. CIMS CALS GPME JOHAKU Etc. CSDP CIM Project CAD Develop. CALS

15. Change of Shipbuilding IT Concept and Approach • from Computer Aided Drafting to Computer Aided Design • from Yard Standard to Industry(International) Standard • from Engineering for Design to Engineering for Production • from Sequential to Parallel(Concurrent) • from Individual to Collaboration • from Geometry ModeltoProduct Model • Product Life Cycle Support • to component software building • to multi-tier application development

16. PROJECT PERIOD 1970s 1980s CSDP 1st half 1990s CIM Project 2nd half 1990s Shipbuilding 2000s CALS CONTENTS MIS, NC, … 2D CAD for Drafting 3D CAD/CAM for Production CIM Information Integration Advanced CAD Development CALS/EC e-Business IT Development History in Korean Shipbuilding

17. CSDP Computerized Ship Design & Production Basic Technology Research Engineering Applications Optimization Technique, etc 1st half of 1990s Consortium KRISO 4 Major Shipbuilders DSME, HHI SHI, HANJIN CIM-Project CIM Project for Shipbuilding 3D Product Modeling Production Planning & Simulation DBMS, Expert Systems, etc 2nd half of 1990s Consortium KRISO 4 Major Shipbuilders DSME, HHI SHI, HANJIN Completed IT Projects in Korean Shipbuilding

18. Shipbuilding CALS Building Infrastructure for e-Business of Shipbuilding Electronic Approval Drawing Exchange 3D Equipment Lib. e-Catalog … 2001 - 2004 (3 Year Project) Consortium IT Consultants/Companies 4 Major Shipbuilders e-Market Place Collaborations for e-Procurement of Shipbuilding 2001 - on-Going Consortium IT Consultants/Companies 4 Major Shipbuilders DSME, HHI SHI, HANJIN On-Going Projects in Korean Shipbuilding

19. DSME CAD Development & Unification Project- Cooperation with TBS (TRIBON) • Project Scope and Concept • Develop integrated system from design to production • Develop optimized solution with verified shipbuilding CAD system • Joint development with commercial CAD developing company(TBS) • TRIBON Mx Series based CAD on Windows environment • Concentrated on the development of Open and Flexible Tribon System • Implementation Time Schedule • M2 : 2002, Q2 = Step 1 items (70 items) • M3 : 2003, Q3 = Step 2/3 items (64 items) • APIs(VITESSE) Development • High Priority for DSME Specific Development Items • Main Area : Draft, Utilities, Pipe, Cable, Structure, Hull Applications

20. Current DSME CAD Environments - Purchasing/Procurement Info. - Review BOM Information Hull DB Hull TRIBON Procurement Limited information sharing Outfitting DB Production Outfitting CADDS5 Problems - Production/Scheduling Info. - Review Design Information • Design information sharing between Hull & Outfitting • Difficult to give production information at real time

21. Production After CAD Unification Environments Integrated DB Procurement Hull Share the Design Information Real time Information Sharing Available Effects • Improve information sharing between hull & outfitting at real time • ▶ Improve design quality and reduce design time • Manage the design and production data in integrated DB • ▶ Effective support of production/procurement information • ▶ Support the information in flexible manner Outfitting

22. Shipbuilding CAD based Systems General CAD based Systems Theory/Concept • Old but proven in the shipyard • Slow/Low performance but stable • Non-parametric solution • New but not proven(no reference) • High performance but sometimesunstable • Associative/parametric solution Usability • Domain specific but easy of use/learn • Familiar commands • Worldwide but hard to use directly as-is • Unfamiliar commands Data Structure • Closed • Light/Compact(no B-rep, no CSG) • File/Sequential & RDB • Own Data Format • Open • General but Huge/Complex • Commercial(RDB, OODB…) • Industrial(International) Standard Focus • Drawing/Production data extraction • Design/Modeling/CAM data Porting • Hard • Easy 3rd Party Applications • Little, hard to integrate • Batch style interface • Many • Integration(plug in style) API • Little APIs(hard to develop) • Many APIs(easy of further develop) Automation • Hard • Easy Comparison of Two Typical Shipbuilding CAD Development Strategies

23. Compartment Hull Surface Scheduling Structure Design BOM Equip. Detail Design Automation FEA Model Structure Model Development of Ship Product Modeling Technologyfor Concurrent Engineering • Nesting • Drawing • NC data generation • etc Product Model

24. What is the Ship Product Model ? • Shipbuilder’s View • CAD model(or data/information) based engineering model for design and production • Including CAE/CAM models and various types of BOM • legacy data/applications porting and using • related standardization activities in ISO : • STEP AP215, 216, 218, 226 and 227 • Ship Owner or Operator’s View • engineering model for ship operating and maintenance • related standardization activities in ISO : STEP AP233 • etc…

25. Challenging Problems for Ship Product Modeling • How to maintain integrity of the information • Optimum level of associativeness for design and information modeling • reduce the information conflict between different disciplines • How to support domain specific knowledge & in-house applications • APIs supporting design, engineering and manufacturing processes • flexibility for the change of IT • How to convert or reuse the legacy data • How to make it easy, simple and light to use • familiar commands & interface, batch operation for tedious job • effective data structure storing huge size model • flexible data structure supporting user attributes(parameters) • Product Model Configuration Management Supporting Multiple Orthogonal Views

26. Examples of the Manufacturing Information Extracted from the Plant Product Model pipe piece drawing beam piece drawing assembly & BOM different CAD interface plate piece drawing report

27. 1 Scheduling Process Logistics Design Integrated Production Planning System • Optimized Production Planning Systems • - Lon-Term, Mid-Term, Monthly, Week & Daily • - “What if” Simulation, Reactive Scheduling • - Minimize Work in Process & Duration • JIT System of Material Flow • Personnel & Resource Planning • Automatic Assembly Block Nesting Long Term Business Planning Mid Term Scheduling Monthly Scheduling Weekly/Daily Scheduling DBMS • Dock Planning • Erection Scheduling • Pre Erection, • Block Painting • Shop Assemble, • Dock/Quay Outfitting • Quay Arrangement Barchart Schedule Optimization Engine [ILOG] Solve Constraints Satisfaction Problems Erection Network

28. CAM in Shipbuilding Simulation on 3D Model & Off-Line teaching CAD data • CAD/CAM Integrated Welding Robot • Automated Cutting & Marking System • Automated Nesting System • Automated Curved Structure • Manufacturing System • - 3-D Block Measuring & Erection Simulation • - Automated Line Heating for Forming • - Auto Pin Jig Information for Curved Block • Etc Shop Working Program Up/Down Load

29. Example of CAM Application Development : Auto Nesting • NC Data Generation • Plate Auto Nesting • Optimization under Constraints • Automatic Drawing Generation • Stiffener Nesting • Parametric Geometry Solver • Auto/Semi-auto Nesting • Tool Path Minimization • Automatic Drawing Generation • Drawing Touch Up • Managed by Database System • Web-based • Design Error Check • Component Programming Tech.

30. Scheduling Process Logistics Design Digital Shipbuilding in Production DBMS • Implement Digital Shop/Shipyard Concept • - Product-Process-Resource Model • - Product Lifecycle Management • Simulation Based Manufacturing • - Shop Layout Simulation & Process Analysis • - Pre Examination of Alternatives • - Minimize risk of failure or delay • Block Location Monitoring System • Etc. Digital Shop CAD Interface Sys. Scheduling Sys. User Define Process Information 3-D Shop Simulator Product Model Process Model Resource Model What if Senario Process Monitoring Sys. Real Time Fabrication Information

31. Future Concerns • Completing and supporting product modeling technology • Simplified & automated modeling procedure • Completion of integration • hull & outfitting • in-house applications • with database • Increasing design & engineering capability • CAE interface • Not only mesh, but also loading and boundary conditions • Supporting multiple orthogonal views • Design/engineering collaboration on the web & PDM • Simulation Based Design & Production Planning

32. Development of Effective Concepts : Simplified Ship Structure Modeling • More than 80% of the ship structures are placed on the planar surface. • webs and frames, bulkheads, stringers, decks, ... • Such a planar structure is represented as symbolic curve or bounded plane with attributes(structural drawing itself) • (ex) using 2D make 3D if necessary s 200X12 fb w drawing for initial design (arrangement, size, material, …) 3D model for production (real geometric image) Converting knowledge

33. Example of Integrated Engineering Applications : Web-based DB for Hull & Basic Designs • Hull Form Design • Geometry • Power Estimation • Resistance • Sea Trial • Design History • Basic Design • Main Dimension • Weight Estimation • Cost Estimation • … • Easy Access & Control (WEB Technology)

34. Example of Integrated Engineering Applications : Geometry & DB Integrated Propeller Design System • Blade Geometry Design (Solid) • Parametic • Wake Analysis • Cavitation Analysis • Power Prediction • Reporting • Propeller Series Management • Database Example of solely integrated propeller design & analysis applications

35. Example of Integrated Engineering Applications :Ship Basic Planning • Volume Definition • Loading Calculation • Stability Calculation • Intact • Damage • Hydrostatic Calculation • Longitudinal Strength • Rules & Regulations Check • Reporting • ...

36. CAD/CAE Interface Applications • Automatic FE mesh generation from the product model for • hydrodynamic analysis • noise & vibration analysis • structural analysis • Based on • the hull surface(surface) model • the subdivision(surface) model • and structure(3D solid, fatigue analysis) model

37. Whole Ship Structural Model from CAD Surface Model (LNG Carrier) Example of the FE Meshes Generated from the Model FPSO Flare Tower for Fatigue Analysis Solid FE Model for Fatigue Analysis FPSO Aft Body Meshes for Structure Analysis

38. Web Server PDM Server Physical Databases PDM in Shipbuilding Database Query (Vendor/Class/Owner) Project Access (Marketing) Information Tracking Project Information Spec, Key-Plan, Document, CAD, Engineering Report Inquiry, BOM, Vendor... (Design) Information Viewing Auto-Transfer (Production) • Data/Process/Work Flow • Product Tree • CAD/OA Connection • PC • Workstation

39. 1 1 1 1 0 0 Setup of PDM Environment for Shipbuilding Engineering Analysis Marketing & Design CAD Product Model Word Processor Other Applications Owner Class Vendor Model BOMs, Drawings SPEC Inquiry, Estimation Electronic Drawing Control ”DIGITAL DATA" Meta-database File Sorage 0 PDM System CAD File Etc. Digital File Word Processor File FEA File

40. Savings time and cost to exchange of design & production data Opportunity to extend electronic data exchange into a production environment Providing faster and more efficient services to business partner Product Data Exchange by STEP • STEP file • Geometry & design data • SEASPRITETM translator • based on the shipbuilding • STEP AP218 ARM subset

41. Examples of Design Review through Visualization Tension Leg Platform(TLP) Detail Design LPG-FPSO Concept Design

42. Grate Control Room Bag Filter Example of Plant Visualization : Incineration Plant

43. Conclusion : IT Development & Application for... • Implementation of Product Modeling Technology : Concurrent Engineering • CAD Unification and Development of Features of Next Generation CAD • Application of New Technologies: Web-based, Parametric, Component, VR... • Integration of CAD/CAM & Production Systems : Shipbuilding CIM • Establishment of Information Share & Management Infra: PDM, ERP • Electronic Business: CALS, e-Marketplace • Increase of Productivity 30% by IT Innovation • Realizing the 21C Digital & Virtual Shipyard