Systems Engineering at Damen Shipyards Applying systems engineering in the concept development phase of standard vessels Master’s thesis - I.H.S. Lely 4107640 TU Delft: J. Pruyn, PhD Damen Shipyards: K. Silvius, MSc Report number: SDPO.18.042.m. Marine Technology November 23, 2018 PREFACE This master’s thesis is conducted as a requirement for the Maritime Masters course ’MT54015 - MSc Thesis’, which constitutes part of the Marine Technology masters program at Delft University of Technology. The fol- lowed master track is the Design, Production and Operation track, with the specialisation in Ship Production (MT-MS-DPO-SP-15). This project responds to the following research question: In what way can systems engineering improve the effectiveness of the concept development phase of High Speed Craft standard projects? Trying to change an existing company culture, which is based on years and years of experience, is a big chal- lenge. My goal is to convince Damen Shipyards that applying systems engineering in the concept development phase ultimately is to their own benefit and I sincerely hope that they will have the courage to implement the proposed framework. Thank you Damen Shipyards for giving me the opportunity to conduct this research. Thank you Kasper Silvius, Maarten Deul from Damen Shipyards and thank you Jeroen Pruyn and Robert Hekkenberg from the Technical University of Delft for your help and critical views throughout the research. Thank you family and friends for the large amounts of support you all showed, in particular to Sarah Rose for supporting me every day and hav- ing the most loyal aunt in the world; Marianne Wolfhagen. Marianne, without your help I couldn’t have done this and I owe you for ever. Enjoy reading this report! Irith Lely Master’s Thesis i Irith Lely SUMMARY The motive for this master’s thesis comes from reoccurring problems at Damen Shipyards with external and internal alignments regarding the product definition, hand-over between sales and project management and quality control during the concept development and execution phases of (standard) vessels. Damen Ship- yards is a Dutch shipbuilding company, founded in 1927 at Hardinxveld-Giessendam. They build, repair and refit vessels off all types, all over the world. The Design & Proposal department (D & P) of the Commercial New Build Division (CNBD) carries out de- sign processes for one-off and standard projects. The demands of the client are captured within the contract specifications and the general arrangement plan, created by D & P by applying the design spiral. D & P also produce the IDC (Integral Direct Cost), which contains amongst other things the estimation of required hours and costs. VTC documents (Variation To Contract) are used to adapt the contract. Contract specifications of standard vessels can be created in a couple of hours by one single D & P engineer. In accordance with Damen Shipyards, the research focuses on the concept development phase of standard projects within the business unit High Speed Craft (HSC) with the aim to improve the effectiveness of the ship design process. The problems encountered during the concept development phase and the execution phase regarding controllability of the design process, and quality and effectiveness of the vessel, are most likely to be solved by changing the approach of the concept development phase. Based on the problem definition, the impact of the problems and the promising potential results of systems engineering, this thesis provides an answer to the following research question: In what way can systems engineering improve the effectiveness of the concept development phase of High Speed Craft standard projects? The field research is conducted to map the current concept development phase at HSC, through numerous interviews with engineers and managers of various disciplines from Damen Shipyards Gorinchem, plus inter- views with external experts in the field of the shipbuilding industry. The theoretical background is based on relevant books, articles, papers and studies and experiences with implementation of systems engineering in other projects of Damen Shipyards. A comparison of five life cycle models (V, DoD, Waterfall, INCOSE-V and Kossiakoff) and the study of various papers leads to a proposed combination of the V-model, the Kossiakoff- model and the SBS structure of Moredo & Krikke, to implement systems engineering. Based on the outcome of the field research and the theoretical background, it is concluded that by perform- ing the proposed framework, the effectiveness of the concept development phase of HSC standard projects is improved. The results include a tailored framework and subsequent guideline, to allow Damen Shipyards to introduce systems engineering in the concept development phase of High Speed Craft projects. Master’s Thesis iii Irith Lely CONTENTS Preface i Summary iii List of Figures 3 List of Tables 5 1 Introduction 7 1.1 Damen Shipyards.........................................7 1.2 Shipbuilding Process.......................................9 1.3 Problem Definition........................................ 13 1.4 Impact of the Problem...................................... 15 1.5 Summary, Scope, Aim & Research Question............................ 17 2 Literature & Research 19 2.1 General Design Approaches.................................... 19 2.1.1 Complexity......................................... 19 2.1.2 Different design spirals.................................. 20 2.1.3 Spiral Improvements.................................... 22 2.1.4 Systems Engineering.................................... 24 2.2 Systems Engineering & Benefits.................................. 26 2.3 Effectiveness in Shipbuilding Processes.............................. 29 2.4 Current Concept Development.................................. 31 2.5 Differences Current Situation and Systems Engineering..................... 36 2.6 Systems Engineering Framework................................. 38 2.6.1 Life Cycle Models..................................... 38 2.6.2 Proposed Framework................................... 42 2.6.3 Transition of procedures.................................. 44 2.7 Costs............................................... 47 3 Conclusions 55 4 Discussion 57 5 Recommendations 59 APPENDICES I A Different FCS Vessels I B CNBD Organisational Chart III C Examples Problems V D Non-Quality Costs IX E Paper J. de Vries XIII F SE Warship at CNBD XV GV&V XVII H Incose Handbook XIX I Moredo/krikke XXI J List of SE standards XXIII K Design Criteria Small FCS XXV L Steps Kossiakoff Life Cycle Model XXXV Master’s Thesis 1 Irith Lely M Acronyms & Abbreviations XXXIX N Bibliography XLI Master’s Thesis 2 Irith Lely LISTOF FIGURES 1.1 Vessel Construction Options - DTC [Source: Damen Shipyards]....................8 1.2 General Shipbuilding Process [Sources: Damen Shiphards; Irith Lely]................9 1.3 Vessel Contract [Source: Damen Shipyards]...............................9 1.4 IDC [Source: Damen Shipyards]...................................... 10 1.5 Design Spiral [Source: Evans, 1959].................................... 10 1.6 Design Process - New standard Designs [Source: Irith Lely]...................... 11 1.7 DTC - Design Gap [Source: Damen Shiphards].............................. 12 2.1 Design Spiral Evans [Source: Evans, 1959]................................. 20 2.2 Design Spirals Watson [Source: Watson, 1998].............................. 21 2.3 Design Spiral Rawson & Tupper [Source: Rawson & Tupper, 2001].................. 21 2.4 Design Spiral Papanikolaou [Sources: Papanikolaou, 2014]...................... 22 2.5 Concurrent (Parallel and Integrated) Product Development [Source: Bennett & Lamb, 1996].. 23 2.6 Allocation of Functional Requirements to Systems Breakdown [Source: Leidraadse, n.d.].... 24 2.7 Tailoring requires balance between risk and process [Source: Haskins, 2006]............ 27 2.8 Theoretical Effectiveness [Source: Veeke et al., 2008].......................... 29 2.9 Actual Productivity [Source: Veeke et al., 2008].............................. 29 2.10 Max. Theoretical and Standard Productivity [Source: Irith Lely, based on Veeke et al., 2008]... 29 2.11 Efficiency [Source: Veeke et al., 2008)................................... 30 2.12 Actual Effectiveness [Source: Veeke et al. (2008)]............................. 30 2.13 System Codes Damen [Source: Damen Shipyards]............................ 31 2.14 Example System Codes Damen - 000 capacities [Source: Damen Shipyards]............ 32 2.15 Example System Codes Damen - 000 Sailing Profile [Source: Damen Shipyards].......... 32 2.16 Example System Codes Damen - 200 [Source: Damen Shipyards]................... 32 2.17 Example System Codes Damen - Hull shape [Source: Damen Shipyards].............. 33 2.18 Current Results & Sacrifices [Source: Irith Lely]............................. 34 2.19 Info from Figures 2.14 through 2.17 translated into Systems Engineering [Source: Irith Lely]... 36 2.20 General Systems Engineering - Results & Sacrifices [Source: Irith Lely]............... 37 2.21 V-model - Dutch Civil Handbook [Source: Irith Lely, based on Leidraadse, n.d.].......... 38 2.22 DoD Process & Model [Source: Calvano et al., 2009]........................... 39 2.23 Waterfall Model [Source: Kossiakoff et al., 2011]............................. 39 2.24 INCOSE: V-model [Source: Haskins, 2006]................................ 40 2.25 SE Life Cycle [Source: Kossiakoff et al., 2011]............................... 40 2.26 SE Life Cycle Explanation