先进造船技术-Tech-R3-1050905

1、2005. 08. 31,Advanced Shipbuilding Technology,2,Korean Shipbuilding Trends,Strength of Korean Shipyards,Status of Korean Major Shipyards,Advanced Ship Design Practices,Advanced Shipyard,As-Is 2004年 HMD 交36艘船，1000亿黑字),着重进行能缩短工期的生产技术开发及工法开发 ( 坞期 : 37天 ) 单元舾装、预舾装率最大化及分段最大化 增加外包 (甲板室、分段、舱口盖等),高附加值为主 Val

2、ue Added,速度经营 Speed Management,韩国的船厂在材料费上升、汇率升值等恶劣的经营条件下通过持续的投资及技术开发，迎来了造船业史无前例的大好形势。 因以钢铁为中心的原材料价格急剧上升等影响收益锐减，但从长期发展的角度出发，不断加大投资及技术开发。,持续的投资,技术开发,为达成生产目标，推进专业化及合作化 (SCM) 为确保经营的透明性及提高企业价值(引进外资)而投资系统 扩大中小型船厂的新建 2015年 1,670万 GT (40%),开发、应用平地建造方法 不断开展设定新目标、节减成本及改善等活动,5,3. Strength of Korean Shipyards,韩

3、国造船业从初期开始通过持续的技术投资和改善管理，克服了薄弱的技术和恶劣的条件，通过不断的改善活动和员工的积极努力，迎来了急速发展。,持续的投资,培养专门人力、相互技术交流，集体研究、持续的培训等,以大型建造设备增加效率、节减成本，持续投资于CAD & I.T领域，扩充设备,技术开发,优秀的人力,改善管理,相关产业 Infra,标准化& 强化管理、目标管理/重点管理、持续的质量管理 (TQC, 提案, IE&VE),积极引进先进技术、持续开发生产技术和建造工法、焊接/Robot技术 JIG & Tool 开发, Process改善等,优秀的造船产业群(钢铁、主机、设备)，培养合作公司，外包,运用

4、信息技术,与硬件并行投资于I.T (信息系统)领域，持续投资等,客户的高认知度,6,4. Status of Korean Major Shipyards,(只限商船),7,4.2 Status of New Shipbuilding for Major Shipyards in Korea,韩国造船厂建造实绩,船型别建造实绩,2004年建造实绩 : 前年同期对比增加 22.2%,Source : The Korea shipbuilder Association 2005.1.,8,5. Advanced Ship Design Technology,Budgeting and Contro

5、lling,Cost Reduction by Material Saving,Improving the Process and Efficiency,Minimizing the Mistake and Corrective Rework,Elimination of Waste,Optimizing the Design and Arrangement,5.1 Professional Design Aim for :,9,5. Advanced Ship Design Technology,Cost-Minded,Advanced,Production-Oriented,Costs S

6、aving for Material & Labor Budget and Controlling,High Performance and High Quality Advanced Design Technology,Easy Production and High Efficiency Simplify and Upstream Policy,Concept,Basic & Detail Design,Production Design,Pre-Nesting, Re-Nesting, Control of Scrap Ratio & leftover Plate, BOM, PML H

7、igh Material Usage, Recycling of Leftover Material Material Cost Saving,3D Modeling, Library, Coding System, ASDP, ADES Interface Check, Prevent Design Error Reduction of Repair and Corrective Rework (Cost Saving for Material & Labor),HAP, CPP, Composite Dwg., Work Package, Structuralized Steel Outf

8、itting Define the Work Process & Sequence Prevent Additional and Extra Work, Minimize Erroneous Work and Corrective Rework,Optimize the Arrangement and System Standardization,Optimized,Integrated,Pipe Route, Cable Route, Number of Pieces, Pipe Support, Cable Tray, Module Unit Saving Material Cost, R

9、eduction of Work Volume,Integrate Design Database with Production, Materials and Logistics (BOM, PML) On-time Work Preparation, Prevent Idle Cost & Time,Integrate Database with CIMS, Production Design, Materials and Logistics,10,6. Advanced Ship Design Practices (ASDP),Hull Design Application Standa

10、rd for Assembly Drawing Application Standard for Cutting, Bending & End Detail Design Guidance for Assembly Drawing Design Guidance for Cutting and Bending Guidance for Steel Material Guidance for Curved Panel, Jig and Remarking, etc. Outfitting Design Design Standard for Piping (Engine Room Piping

11、and Hull Piping) Design Standard for Engine Room Outfitting Design Standard for Hull Outfitting Design Standard for Accommodation & HVAC Design Standard for Electric Outfitting,Contents of HANA ASDP,Direct Benefits Cost Reduction by Material Saving Labor Cost (Construction Man-hours) Speed up Produc

12、tion Benefit for Design and Production Improve Design and Production Efficiency Prevent Erroneous Work and Corrective Rework Other Benefits Benchmark & Catch up Advanced Practice Enhance Technical Standard & Quality Improve Design & Production Technology Gradually Reduce Construction Man-hours,Impro

13、ve Design Efficiency by Standardization Design Practice, Guidance, Check List, etc. Numbering System, Symbol & Abbreviation Representation Methods Simplify for Repeated Plain Design Work,ASDP Focused on :,Benefits Enjoyable with ASDP,11,7. Auto Design & Engineering System (ADES),HANA ADES Focused on

14、 :,将使用者必需的信息加工成必要的形态而提供,弥补设计工具的不足点，提高设计效率,提供支持，使之能够早期提供必需的信息,设计信息的体系管理,通过System (CIMS) Interface，使数据输入自动化,使设计人员简单重复工作最少化的图纸自动化,12,8.1 Key Concept,8. Shipyard Management Information System,13,8.2 Core of Management System,Shipyard Management System的核心要素是什么?,Material & Material Flow,Design,Production,

15、Prod. Sch.,Material, Lead Time,Design Plan,Prod. Sch.,POR, POS,Material Problems,设计/物资/生产的同步化,生产为主,Shipbuilding Process 确立,Yard Standard Data,Advanced Practice,Management Concept,Shipbuilding Features,Real-Time Monitoring & Control,同步化的计划(Master/Erection Schedule, 先行中日程计划 DP/MP W/P & W/O 部门生产计划、周/日计

16、划 W/O) 通过信息共享的实时监控&业务处理 通过标准及出厂船数据，容易制订计划 通过实绩数据统计/分析的成本统计、目标管理等,及时供应物资 及遵守工程,通过实绩统计/ 分析的目标管理,工作量,BOM,现场问题,要求物资,剩余库存,造船厂经验 & 管理 System, Know-How,船厂核心功能 通过信息化增加 生产量、提高效率,14,8.3 System Interface,HANA-PRO CIMS,Tribon,Outsourcing Contract Quality Management Facility Maintenance Sales Management, etc.,Ov

17、erall System Configuration of HANA-PRO CIMS,ADES,ADES Hull,ADES Outfitting,ADES PID,Prime Module,Common Information System Production Management System Design Management System Material & Material Flow Management System,Optional Modules for Further Application,CAD Library,Modeling Data,Project DataB

18、ase,Data Processing Data Generation Data Extraction,Data Transfer (BOM, PML),Major Functions of ADES Auto- Drawing Auto-Generation of Production Drawing Auto-Generation of Production Information,15,Sales Management,Vehicle Mgt.,Block Transfer Mgt.,Facility Maintenance Mgt.,Executive Information Mgt.

19、,Budget & Cost Mgt.,Common Information,Production Management,Material Management,Quality Management,Design Management,Computer Integrated Management System,8.4 Configuration of HANA-PRO CIMS,16,9. Advanced Production Technology,9.3 Mega Block Production,9.5 Skid Launching System (SLS),9.6 陆上(Ground)

20、 建造下水 工法,9.2 Unit Module Production,9.4 分割建造方式,9.1 Slit Method,17,9. Advanced Production Technology,9.1 Slit Method,18,SLIT Method,19,20,21,22,23,24,25,26,27,28,29,9. Advanced Production Technology,9.2 Unit Module Production,30,31,32,33,34,Composite Drawing Sample,35,36,9. Advanced Production Techno

21、logy,9.3 Mega Block Production,37,38,39,40,41,42,43,44,45,46,47,48,49,50,51,52,53,54,55,56,57,58,59,9. Advanced Production Technology,9.4 分割建造方式,60,61,1月6日第一次Load-Out,62,63,1月8日第二次Load-Out,64,9. Advanced Production Technology,9.5 Skid Launching System (SLS),65,9. Advanced Production Technology,9.6 陆

22、上(Ground) 建造下水 工法,66,陆上(Ground) 建造 下水 工法,67,10. Advanced Shipyard,1) Steel Stock Yard,2) Pre-treatment Line,4) Subassembly Shop,3) Recycling Plate Stock Area,5) Panel Block Shop,6) Curved Block Shop,7) In-Shop Block Outfitting,8) Module Unit Shop,9) Pre-Erection Area,10) Dry Dock,11) After Launching

23、,12) Quay Side,68,11. Construction of Value Added Vessels,1) Large Container Carrier,2) FPSO,4) LNG-RV,3) LNG Carrier,69,Market Share for Large Container Carrier,Japan: 9.25%,Korea: 75.6%,2004年(1月-9月),单位:%,资料：大韩造船工业协会,70,71,72,FPSO,73,74,LNG船世界市场订单率,2004年(1月-9月),单位:%,韩国:71%,日本:28.9%,中国:0%,资料:大韩造船工业协

24、会,27艘,11艘,75,Membrane Type,Moss Type,LNG Carrier,76,77,78,79,LNG-RV,80,81,12. As-Is & To-Be of Shipyards,As-Is (现象 & 问题),To-Be (改善方向),5. 未具备基础秩序,4. 较差的Infra & 社会结构,3. 缺乏问题解决能力及责任意识,1. 过分偏向于硬件和劳动力 (短期观点，着重于设施， ),2. 技术投资及改善努力不足,5. 遵守基础秩序生活化，持续的培训等,4. 改善与合作公司的关系(技术指导、信息共享等)及意识改革,3. 管理改善及责任和权限的明确化 持续的业务

25、改善和经营革新活动,1. 与设备投资一起需要制订综合经营战 略。制订发展目标,2. 通过引进先进技术，尽早确保技术和强化内部力量,大部分为国营船厂，管理和效率比较差。 需确保竞争力,82,13. Main Tasks for Future Growth,Tasks,Solution,将国有企业的文化转换为民营企业水准的竞争体制,提高管理能力及水准,No.,确保稳定的技术能力,意识改革&开展活动,推进持续的改善活动,中国船厂要想在短时间内赶超日本/韩国需在如下观点找到解决办法(船厂中心),通过责任经营体制，赋予权限和责任(总经理中心) 引进与业绩挂钩的信赏必罚(补偿体制)制度等,通过Proces

26、s改善/ System引进、应用，提高管理能力 通过外部咨询、内部学习组织化等，提高水平 优秀人才的培养及持续的培训等,通过引进先进技术及加强自身力量，早期确保技术能力 生产技术/建造工法/焊接技术等的持续技术开发等,为经营革新、意识改革准备制度及进行内部教育 为管理革新开展持续的活动,开展全公司改善活动(提案活动、班生产会议、TFT等) 通过外部专家不断改善等,83,14. Q/A about Shipbuilding Performance,Comparison of Light Ship Weight , Labor Man-Hour,84,14. Q/A about Shipbuild

27、ing Performance,Comparison of Number of Pieces,Unit : Pieces,Excluding Accommodation Area,85,14. Q/A about Shipbuilding Performance,Comparison Competitiveness of Korea/Japan/China (2015),Analysis of Competitiveness,(from “Korea Industry Institute, 2004. 9”),Capability of China : 2005年约700万GT, 2010年

28、1,000万GT, 2015年世界第一目标 (Ex:CSSC“531计划”, 韩国预计2015年为1, 670万GT-40%) 韩国预计通过持续的核心技术及产品开发推进高附加值化/差别化，在高附加值船型中维持稳定的市场份额 (5065%),中国政府支持 : 以国轮国造政策为基调，预计重点支持大型油轮、LNG、高速客船、FPSO、 海上平台、船用主机等项目,为确保竞争力，设计/生产/管理等多方面的努力要与设施投资并行,86,14. Q/A about Shipbuilding Performance,Case Study for Effect of CIMS Implementation,No.

29、 of vessels delivered in 97 (42 ships),Incorrect Supply of Material out of JIT and Right Place,2,550,000,120,000,Delay of Supplying Equipment to Production Need Date,1,610,000,80,000,Equipment Failure,890,000,20,000,Design Mistakes,650,000,180,000,Production Errors,430,000,250,000,Total,6,130,000,65

30、0,000,Saving 5.48 millions M/H,Causes of work loss,Lost Man-hour in 91,Lost Man-hours in 97,Remark,1,2,3,4,5,No.,87,14. Q/A about Shipbuilding Performance,Production Design Period and Work Load Distribution,Time Schedule,Work Load,Above Work Load Curve is an average value for designing of experience

31、d type of Vessel but the time schedule and work load will be increased by 40 80% for the designing of New Vessel. Above Time Schedule and Work Load Distribution Curve is based on accumulated experience in ship design over 20 years. This is the most reliable data for time schedule and Design Work Loa

32、d Distribution to minimize the corrective rework for the design and production. In the shipbuilding business, we are inescapable from the revision drawings, mainly caused by inadequate design interval between the Dept., and consequential affects of corrective rework for the design & production. In o

33、rder to Minimize the Corrective Rework, It is only way that we have to optimize the design interval and period to be incorporated relevant information on the drawings just in time. ,Contract,K/L,D/L,S/C,L/C,Tandem Period,(For Example: Typical Type of Vessel),88,Structuralized Outfitting Items Hole P

34、lan Carling,Block Division Lines Faring Landing Seam Arrangement,Pre-nesting Assembly Division Process,Interface Check between the Design Stages,Hull Structural Drawings Outfitting Arrangement,It is very important real-time communication and information sharing between the Hull Design and Outfitting

35、 Design Dept.,Lines G/A,Key Plans Basic Calculation,Basic Design,Detail Design,Hull Production Design,Outfitting Production Design,14. Q/A about Shipbuilding Performance,89,Appendix 1. Comparison of Work Efficiency & Performance,Traditional Shipyard,Advanced Shipyard,Steel Storage,1. Steel Plates ar

36、e not properly stored - Loss for Surface Preparation - Adhesion problem with Shop-primer - Defect on Steel Plate 2. Waste of time to sort out the plates and Cranes are heavily loaded,1. Steel Plate are stored properly in accordance with production schedule as planned,90,Appendix 1. Comparison of Wor

37、k Efficiency & Performance,Traditional Shipyard,Advanced Shipyard,Steel Storage,91,Appendix 1. Comparison of Work Efficiency & Performance,Traditional Shipyard,Advanced Shipyard,Steel Cutting,92,Appendix 1. Comparison of Work Efficiency & Performance,Traditional Shipyard,Advanced Shipyard,Buffer Are

38、a in Workshop,1. Remaining steel plates are not properly organized after processing and cannot be identified for recycling 2. Buffer area is not enough and disorganized for processed semi-products 3. Waste of time and money,1. Allocate steel plates at Stand-By Location 2. Well organize Buffer Area f

39、or processing and processed semi-products. 3. Save time and cost, improve Productivity work Efficiency and Safety,93,Appendix 1. Comparison of Work Efficiency & Performance,Traditional Shipyard,Advanced Shipyard,Temporary Storage of Processed Semi-products in Shop,1. Scattered semi-produced pieces a

40、nd remaining materials all-around of the Workshop - Poor Management - Low Efficiency 2. Not available Recycling of Remaining Materials,1. Palletize the processed semi-products ,94,Appendix 1. Comparison of Work Efficiency & Performance,Traditional Shipyard,Advanced Shipyard,Sub-Assembly,95,Appendix

41、1. Comparison of Work Efficiency & Performance,Traditional Shipyard,Advanced Shipyard,Temporary Storage of Processed Semi-products to allocate next stage,96,Appendix 1. Comparison of Work Efficiency & Performance,Traditional Shipyard,Advanced Shipyard,Unit System,97,Appendix 1. Comparison of Work Ef

42、ficiency & Performance,Traditional Shipyard,Advanced Shipyard,Unit Production,98,Appendix 1. Comparison of Work Efficiency & Performance,Traditional Shipyard,Advanced Shipyard,Block Outfitting,99,Appendix 1. Comparison of Work Efficiency & Performance,Traditional Shipyard,Advanced Shipyard,Block Out

43、fitting,100,Appendix 1. Comparison of Work Efficiency & Performance,Traditional Shipyard,Advanced Shipyard,Block Outfitting,101,Appendix 1. Comparison of Work Efficiency & Performance,Traditional Shipyard,Advanced Shipyard,Block Outfitting,102,Appendix 1. Comparison of Work Efficiency & Performance,

44、Traditional Shipyard,Advanced Shipyard,Block Erection,103,Appendix 1. Comparison of Work Efficiency & Performance,Traditional Shipyard,Advanced Shipyard,Installation of Rudder System,1. Utilize old-fashioned Scaffolding for Installation,1. Utilize Advanced Jig for Rudder Installation,104,Appendix 1.

45、 Comparison of Work Efficiency & Performance,Traditional Shipyard,Advanced Shipyard,Excessive Scaffolding at Stern Area,1. Utilize old-fashioned Scaffolding for Installation,1. Utilize Advanced Jig and Cherry Picker,105,Appendix 1. Comparison of Work Efficiency & Performance,Traditional Shipyard,Adv

46、anced Shipyard,Excessive Scaffolding,1. Utilize old-fashioned Scaffolding for Installation,1. Utilize Advanced Jig and Cherry Picker,106,Appendix 1. Comparison of Work Efficiency & Performance,Traditional Shipyard,Advanced Shipyard,Dock Installation,1. Poor Rate of Pre-Outfitting,1. Maximize the Pre

47、-Outfitting,107,Appendix 1. Comparison of Work Efficiency & Performance,Traditional Shipyard,Advanced Shipyard,Dock Installation,1. Poor Rate of Pre-Outfitting,1. Maximize the Pre-Outfitting,108,Appendix 1. Comparison of Work Efficiency & Performance,Traditional Shipyard,Advanced Shipyard,Warehousin

48、g,109,2. Main Business Area,1. Introduction,4. Core of HANA-PRO CIMS,3. Main Products,5. Configuration of HANA-PRO CIMS,Appendix 2,110,2. Main Business Area,1. Introduction,4. Core of HANA-PRO CIMS,3. Main Products,5. Configuration of HANA-PRO CIMS,Geo Shipbuilding & Marine Tech Co., Ltd.,Company Pr

49、ofile,Appendix 2,111,1. Introduction,HANA Information Technology Co., Ltd. is a only company to provide Total Solution for Ship Design, Marine Engineering and Highly Integrated Shipbuilding Management Information System.,Based on wide experience in the Ship Design and Integrated Shipbuilding Management Information System, HANA Information Technology Co., Ltd. provides total solution for saving production cost through improving overall ship design and shipbuilding business process.,Appendix 2,112,2. Main Business Area,Appendix 2