A reopened shipyard is faced with a number of challenges in a new situation with a reduced size terrain and a reduced number of production facilities. During the start of operations at the reopened shipyard, a simulation model is developed to assess production capacity and to analyze layout variations and resource utilization for specific schedules. This paper details the development, validation, and use of the model. Because of the early stage of operations in which the model is developed, there exists a lack of detailed information on the production process and on product data. Together with the research objectives this situation calls for a high level model. To make model input straightforward and available in the preliminary design phase, a generic approach to product data input and schedule generation using production material classification is proposed. Qualitative validation is achieved using the judgment of shipyard experts, and quantitative validation is partly achieved by comparing actual production data with simulation model output.In conclusion, the simulation model is a useful tool for production capacity forecasting. It allows for the identification of resource utilization conflicts and limitations, and it supports decision making when considering layout and process alternatives. For example, the model was used to make a quantitative analysis of a proposal to invest in an alternative layout. The result supports the decision to invest in an external panel lane. The schedule generation concept proposed in this paper enables early schedule testing and optimization. A positive byproduct of model development in close cooperation with shipyard experts is the continued awareness it creates concerning production efficiency amongst staff. Two modelling assumptions that significantly limit the applicability of the model are the assumption of unlimited supply of materials and the fact that workforce allocation is not priority based, but instead it is assumed that workers are assigned to production units uniformly during lead time. It would be worthwhile to simulate delays in the supply of components to research the effect on the production process, and to develop a more realistic workforce allocation method. Other recommendations for further research are: Experiment with variable block size to assess the impact on efficiency, Experiment with alternative production floor arrangements to find optimum configuration, generate production material information from 3D CAD (Computer Aided Design) files, Continue the development of schedule generation method.
Simulation based production capacity analysis of a new shipyard
Simulationsbasierte Produktionskapazität einer neuen Schiffswerft
2008
12 Seiten, 11 Bilder, 4 Quellen
Aufsatz (Konferenz)
Englisch
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