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Final Report EVALUATION OF SHIPBUILDING CADICAM SYSTEMS (PHASE I) Submitted to: U.S. Navy by: National Steel & Shipbuilding Co. San Diego, CA 92186 Project Director: John Horvath Principal Investigator: Richard C. Moore October 1996 Technical Report Documentaition Page- 1. Report No. 2. Government Accession No. 3. Recipient's Waiog No. I I 4. Title and Subtitle I 5. Repon Date October 14. 1996 Evaluation of Shipbuilding CADICAM Systems 6. Performing Organization C e (Phase I) '32%'2.7 8. Performing Organization Report Ilo. 7. Author(s) Richard C. Moore UMTRI-96-35 9. Performing Organization Name and Address 10. Work Unit No. (TRAIS) The University of Michigan Transportation Research Institute 11. Contracl or Grant No. 290 1 Baxter Road, Ann Arbor, .Michigan 48 109-2150 PQ# MU7.56606-D - 13. Typ of Report and Period Coverud 12. Sponsoring Agency Name and Address Technical National Steel & Shipbuilding Co. 28th St. & Harbor ~r. 14. Sponsoring Agency Code San Diego, CA 92 1 13 US. Navy 15. Supplementary Notes 16. Abstract This report is the Phase I final report of the National Shipbuilding Research F'rogram (NSRP) project (Project Number 4-94-1) to evaluate world-class shipbuilders' existing CADICAMICIM system implementations. Five U.S. shipyards participated in this study along with personnel from University of Michigan, Proteus Engineering, and Cybo Robots. Project participants have backgrounds in design, computer-aided design (CAD), n~anufacturingprocesses, computer-aided manufacturing (CAM), production planning, and computer-integrated manufacturing/management (CIM). The results of this evaluation provided the basis for the CADICAMICIM Workshop presented in conjunction with the 1996 Ship Production Symposium, and will be used as background in Phase I1 of the project to develop requirements for future shipbuilding CADICAMICIM systems. Shipbuilding, CAD, CAM, CIM, computer systems, integration. I 20. Security Classif. (of this page) 21. NO. of Pages 22. Price Unclassified Unclassified 180 Evaluation of S hipbuilding CADK3AMICI.M System Implementations Table of Contents ACKNOWLEDGEMENTS 1.0 EXECUTIVESUMMARY 2.0 BACKGROUND AND IN'TRODUCTION 2.1 Background 2 -2 Report Organization 3.0 SIGNIFICANT FINDINGS 3.1 Shipbuilding Business Objectives 3.2 TeclmologyAligpme~nt 3.3 Imp kmentation Strategies 3.4 Cap abilities and 0pe:rations 3.5 Application Commonalities 3.6 Unique Implementations Odense Shipyard Overview Busmess Strategy Cornpet itive Strategies Automat ion Major CADICAM Systems Planning and Control CADKIAM ICIM Integration R&D Progams Purchasing and Vendor Relationships 5.0 MITSUBISHI HEAVY IINDUSTRIES 5.1 Nagasaki Shipyard Cherview 5.2 Business Strategy 5.3 Competitive Strategies 5.4 Automation 5.5 M ajar CADCAM Systems 5.6 Planning and Control Systems 5.7 CADtCAMlCIM Integration 6.0 HITACHI ZOSEN 6.1 Ariake Shipyard Overview 6.2 Business Strategy 6.3 Competitive Strategies 6.4 Automation 6.5 Major CADICAM Systems 6.6 Planning and Control Systems 6.7 CADtCAMICIM Integration 7.0 ISHIKAWAJIMA-HARTMA HEAVY INDUSTRIES 7.1 Kure Shipyard Overview 7.2 Busmess Strategy 7.3 Competitive Strategies 7.4 Factory Automation 7.5 Major CADICAM Systems 7.6 Planning and Control 7.7 CADICAMICIM Integration 8.0 HOWALDTSWERKE-DEUTSCHE WERFT AG HDW Shipyard Overview Busmess Strategy Competitive Strategies Automat ion M ajor CADKAM Systems Norddeutsche Informations-Systeme GmbH SM K Ingenieurburo Logimatic and Careironic 9.0 VEXOLME 9.1 Verolme Shipy ard Overview 9.2 Business Strategy 9.3 Competitive Strategies 9.4 Automat ion 9.5 Major CAD/CAM Systems 10.0 KOCKUMS COMPUTER SYSTEMS (KC9 10.1 TRIBONOvewiew 10.2 Implement ation Approaches 10.3 ProductModelingTechnology 10,4 Integration 10.5 TRIBONFutures 11.0 SENERMAR 1 1.1 FORAN Ovewiew 1 1.2 Implementation Approaches 1 1.3 Product M odeling Technology 1 1.4 Integration 11.5 FORAN Futures 12.0 INTERGRAPH 12.1 ISDP Overview 12.2 Imp tmentation Approaches 12.3 Product Modeling Technology 12.4 Integration 12.5 ISDP Futures 13.0 HICADEC 14.0 BLACK & VEATCH 14.1 PO WRTRAK Overview 14.2 Black &Veatch UsagBenefit s 14.3 OtherFindings 15.1 Industrial Technology Institute 15.2 Comput ervision 15.3 Othm Findings APPENDICES A Quality Fundion Deployment B "A-BC Planning Philosophy" at Odense C Steel Production and Outfitting at Odense D Hitachi Zosen Robotics and Aut ornated Welding E Hitachi Zosen Production System Applications F Survey Responses G Participants ACKNOWLEDGMENTS The authors gratefully acknowledge the assistance provided by the following companies, which made this study possible: Black and Veatch Caretronic Ingenieurburo GmbH Hitachi Ariake Works Howaldtswerke-Deutsche Werft AG Industrial Technology Institute Ishikawajima-Harima Heavy Industries Intergraph Kockurns Computer Systems Lclgimatic Marine Consultants A/S Mitsubishi Heavy Industries Norddeutsche Informations Systems GmbH Odense Steel Shipyard Sener Ingenieria y Sistemas SMK Ingenieurburo Verolme Scheepswerf Heusden b.v. The special support and encouragement of Torben Anderson at Odense Stee:l Shipyard was especially appreciated. Without his able assistance in organizing the evaluation visits, and his participation in the Ship Production Symposium CADICAMICIM Workshop, this evaluation could not have been accomplished. Similarly, the assistance of Axel Schroeter at SMK Ingenieurburo is especially acknowledged. He was instrumental in organizing the evaluation of shipyards utilizing commercial shipbuilding software systems and their supporting consultants and suppliers. A list of participants on the shipbuilding CADICAMICIM evaluation project team is included in Appendix H. Likewise, the participants from the above organizations are also listed. The preparation and open discussion by these participants was instrumental to these evaluations. 11.0 ExECUTrn SUMMARY Commercial shipbuilding orders have been increasing worldwide and, for certain product segments, are expected to experience continued strength, possibly for several decades. This follows a 10+ year period during which weak demand could not sustain the available capacity resulting in subsidized prices, voluntary production limits, and numerous shipyard consolidations and closings. With an eye to the more recent market expansion, new capacity is now being added, most notably in regions previously not participatiing in any significant shipbuilding. These regions tend to enjoy labor cost, currency exchange rate, and modern facility advantages over the world's traditional shipbuilders in Europe and Japan. The world's traditional leading commercial shipbuilders have not been idle. In efforts to compete profitably i11 today's shipbuilding markets characterized by over- capacity and extreme price pressures, these yards have developed various strategies to reduce shipbuilding costs and schedules significantly. The strategies include aggressive business practices, new or significantly enhanced computer technologies, factory automation, capital investments, and anpnfaltering attention to process discipline and continuous process improveme:nt. Computer-Aided Design (CAD) technology has been evolving in these shipyards since the 1970s. In the late 1980s and early 1990s this iechnology has been significantly enhanced through the addition of Computer-Aided Manufacturing (CAM) and factory automation, especially in cutting and welding. 'The 1990s is seeing the integration of these engineering and production technologies wit11 planning and business systems'. Truly Computer-Integrated Manufacturing (CIM) is emerging as one of the technologies of the 1990s by which world-class commercial shipbuilders plan to maintain or return to profitable competition in world markets. This project's Phase 1 Assessments of shipyards and software developers provides both overview and depth into "world class" commercial shipbuilding operations. Shipyards in both Europe and Japan, which combined profitable operation and extensive use of computer technology in their operations, were initially studied. Later, specific assessments were conducted regarding use of commercially available CADICAM shipbuilding software in smaller or "2nd tier" shipyards. All of the shipyards studied have some of the highest average labor rates and the lowest labor content per CGT (compensated gross ton). These yards were selected in order to provide the best information^ concerning possible direction for U.S. shipbuilders approach to new CADICAMICIM systems to achieve even better results than those studied. Our assessments indicate that this performance is a result of aggressive business practices that: provide on-going market share and business backlog; continue profitable operation in spite of relentless price and schedule competition; use the best practices available related to people, processes, facilities and technology. This report concentrates on the specifics of technology, but it is not possible to de- couple technology from the other factors listed above. Specifically, we have observed that certain technologies - in particular CADICAMICIM and accuracy control - are essential enabling ingredients in 1996 "world class" commercial shipbuilding. However, effective CADICAMICIM and accuracy (i.e. elimination of variations) technologies are not the only deciding factors. The assessed shipyards represent the survivors of significant industry reductions in both Japan and Europe. These shipyards have adopted strategies that produced improved business results primarily through continually reducing materials costs and labor content. Lower
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