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2/17/2012
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1University of Rostock | Naval Architecture and Ocean Engineering February 2012University of Rostock | Naval Architecture and Marine Engineering
Title: “Modeling & Simulation of a Production line(Panle line) in Shipbuilding Industry using Tecnomatix Plant Simulation 9.0”
Author: Yohannes Tekle Muhabie
Rostock ,Germany February 7, 2012
2University of Rostock | Naval Architecture and Ocean Engineering February 2012
Presentation Outline
► Introduction
► Objective
► Research Methodology
► Flow Chart
► Data Collection & Synthesis
► Model Development
► Scenario Analysis
► Interface with MS Office
► Conclusion
3University of Rostock | Naval Architecture and Ocean Engineering February 2012
Introduction/Overview of ship building Industry
Ship Yard
Ship Owner/Operator
Model Testing
Suppliers Engineering offices
Classification society
•One of a kind •Multiple systems •No percentage completion
Characterized by
4University of Rostock | Naval Architecture and Ocean Engineering February 2012
Objective of the thesis
► General Objective ► Analyze and optimize the panel line
► Specific Objectives ► Data identification and synthesis
► Model and simulate the panel line
► Bottleneck identification
► Investigating the effect of new work station
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5University of Rostock | Naval Architecture and Ocean Engineering February 2012
Research Methodology
Literature Review Books, Journals, Articles, Manuals, people etc.
Data Collection Spread sheet and drawings
Analysis and Synthesis Converting the data in to suitable format
Model Development Representation
Verification & Validation Checking the developed model against some checklists
Scenario Analysis Developing alternative solutions
Conclusion Summarizing the results
6University of Rostock | Naval Architecture and Ocean Engineering February 2012
Steel Structure Production Sequence
Ref. Ship production Lecture note ( Permission from Dr. Ulrich Kothe)
Panel Line
7University of Rostock | Naval Architecture and Ocean Engineering February 2012
Flow chart
Start
is data suitable ?
End
Sankey Diagram
Modeling
Verify and Validate
Scenario Analysis
Documentation
Date PreparationYes
No
8University of Rostock | Naval Architecture and Ocean Engineering February 2012
Date Collection and Synthesis
► Data Available ► Spread sheet from P and S ship yard (Container Ship)
► Drawing (Tanker Ship )
6 plates 5 welds
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9University of Rostock | Naval Architecture and Ocean Engineering February 2012
Sankey Diagram, Cycle and Takt time (Container)
0
50
100
150
200
250
Cycle timeminute
Takt timeminute
17%
12%
13%
Input
S1
S2 S3
S4 S5 S6 Output
49%
39%
19%
61%
7%
32%
61%
S1 S2 S3 S4 S5 S6
-48.1
12.7 -14.9 -5.9
76.6
4039 sheets/yr
Bottleneck
82 67.1
10University of Rostock | Naval Architecture and Ocean Engineering February 2012
Model Development (Tecnomatix Plant Simulation 9.0 )
Assumption: 99% availability MTTR : 2 minutes
3996 sheets/yr
•It is a discrete event simulation (DES) program
Bottleneck
11University of Rostock | Naval Architecture and Ocean Engineering February 2012
Verification and Validation of the Model
► Does it provide utilization of each work station?
► Helps in decision making process (PPC)?
► Are the results easy to understand and interpret ?
► Does it indicate the influence of each workstation?
► Effect of adding a new work station ?
The following check lists have been taken into account
12University of Rostock | Naval Architecture and Ocean Engineering February 2012
Improving production rate (Experimental Manager)
3900
4000
4100
4200
4300
4400
4500
4600
50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82
Nu
mb
er o
f sh
eets
Cycle time (Minute per sheet)
OutPut
OutPut
=(4451-3996)/3996*100%
=11.4% improvement
4451 sheets/yr
Points for improvement:
• Additional manpower hiring •Improving the technology •Future demand
Profile welding
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13University of Rostock | Naval Architecture and Ocean Engineering February 2012
Profile welding and Completion Combined
Experiment
Profile welding
Minute
Completion
Minute
Output
Sheets
16 50 65 5041
40 51 65 5041
64 52 65 5041
88 53 65 5041
112 54 65 5041
136 55 65 5041
160 56 65 5041
184 57 65 5041
208 58 65 5041
5041
=(5041-3996)/3996*100%
=26.2% improvement
14University of Rostock | Naval Architecture and Ocean Engineering February 2012
Adding new work station (PVPs station)
Purpose: Analyzing the effect of new work station
Parameters:
�One stiffened panel comprises 2.25 sheets
�Ten points for proper placement of PVPs (0.5 minute each)
�Robot welding
�Speed , V=0.0083 m/s
�Length, L=2.8 m
Single run, time=L/t= 5.62 minutes
Considering 4 runs to entirely weld the PVPs = 4*5.62=22.5 minutes
Total time for a single PVPs operation = 28.5 minutes
PVPs
15University of Rostock | Naval Architecture and Ocean Engineering February 2012
Cycle time (PVPs ) Station
0
20
40
60
80
100
120
140
160
0 1 2 3 4 5 6 7 8 9 10 11 12 13Cyc
le t
ime
(Min
ute
per
sh
eet)
Number of PVPs per Panel
Cycle time (PVPs)
Cycle time
3994 sheets/yrNo significant effect
3695 sheets/yr
Decline by 7.5 %
PVPs=6
PVPs=7
16University of Rostock | Naval Architecture and Ocean Engineering February 2012
Genetic Algorithm (GA)
GA helps to find out an optimal solution based on a stochastic
approach and it starts with an initial random solution set [20].
Objective: Maximize Production rate
Subject to :
30<=X1<=54.4 / Profile setting station/
50<=X2<=82 /Profile welding/
50<=X3<=73 /Completion/
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17University of Rostock | Naval Architecture and Ocean Engineering February 2012
Genetic Algorithm (GA)
X1=33, X2=50, X3=506497 sheets
Tanker Ship
X1=40, X2=40, 8120 sheets
Container Ship
18University of Rostock | Naval Architecture and Ocean Engineering February 2012
Integrating Ms Access and Excel in the process
Input Data
MS-Access
Process
Plant Simulation
Software
Output
MS-Excel
Connection (ODBC)
Accessing the data
from the Database
Exporting the
resultsCopying and saving the
data in the simulation
table (Operation sheet)
Passing the data to the
objects (machines) in the
station
Performing simulation and
saving the results in to a
table
19University of Rostock | Naval Architecture and Ocean Engineering February 2012
Data consistence
Due attention has been given for data consistence. For example :
Description MS Access Simulation
Processing Time Integer(Second) Time
Processing time
ConstantNormal Distribution
Mean, Stream and standard deviation
Mean
20University of Rostock | Naval Architecture and Ocean Engineering February 2012
Conclusion
�It facilitates the decision making process
�Profile welding is the station where due attention has to be given
�It is suitable for new work station design
�Max number of PVPs are 6 and 4 for Container & Tanker
respectively
Future work :
�Cost benefit analysis has to be incorporated
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21University of Rostock | Naval Architecture and Ocean Engineering February 2012