Simulation of Dispatch Operations at Bidvest Panalpina Logistics
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Simulation in Production and Logistics
at FlensburgerExperiences from the Future
Dirk SteinhauerHead of Simulation Team
Department for Research and [email protected]
APPLIED SIMULATION – A SYMPOSIUMLyngby, 07.11.2013
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Flensburger Shipyard
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Company Data of Flensburger Shipyard
� Established in 1872� 730 employees� 3-4 ships p. a. up to 220m in length� Turnover app. €200Mio� Key competences:
• Steel production• System integration• Research and development
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Flensburger‘s Product Mix
EGV Class 702
Ro Ro 2700
Ro Ro 3900
Ro Ro 2700 for AWSR
Ro Pax 1500
Con-Ro 1000/4600
RoPax Ferry for BC Ferries
Ro Pax 3200/650
Ro Pax 2400/600
Ro Ro 3200
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Current Orders at Flensburger Shipyard
ConRo for Oceanex
2 project cargo vessels for Rolldock
2 seismik ships
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Characteristics of Production in Shipbuilding
Complex product
One-of-a-kind production
Compactproduction
Chaining of different production principles
Building dimensions
Inhomogeneity of utilisation
0
10
20
30
40
50
1 2 3 4 5 6 7 8 9 1 0 1 1 1 1 1 1 1 1 1 20
Variety of parts
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Simulation: Dynamic Model of Production System
System (production/log.)
plants / transp. meansworkers
workplaces stock
process
Schleifen
Schweißen
Montieren
Dynamic Model
Input data
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The Plasma Cutting Planton the Panel Line
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Simulation Model of the Plasma Cutting Plant
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The Simulation Tool for Cutting PlantsSTS_CuttingPlant
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Programs for Cutting Plants
Control of the modul cutting plant
Interface toNum. Code
�Plate owns attribute NC-File
�NC-File is read and translated
Generating Num. Code
�Plate owns geometr. attributes
�NC-File is calculated from geometrical data of plate and panel
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Reasons for Using Simulation in Production and Logistics
� Detailed analysis of production or logistic systems
concerning dynamic relationships and interactions
� Cost efficient trials without any risk
• New production facilities or concepts
• New ships
• New plans
� Transparency of processes
� Objective basis for communication
� Planning reliability
� Flexibility in planning
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Application Fields for Simulation ofProduction and Logistics at Flensburger
Facility layout planning
Production planning
Production flow
Civil engineeringPort logistics
Loading / dischargingof ships
Offshore wind parks
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Development of Simulation ToolsUsing Plant Simulation (Siemens PLM / Tecnomatix)
Simulationtools
Transportcontrol
Crane
Shift calendar
Pre-Production
Applications
Logistics
Ship‘s Logistics
Outfitting
Final Assembly
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Philosophy of STS (Simulation Toolkit Shipbuilding)
� Efficient and effective model building� Implementation of well-proven modelling approaches� Provision of best practice scenarios� Individual adjustability of models
• Interfaces for user rules and specific settings
� Cooperative development• SimCoMar• SIMoFIT• Technical University of Berlin
� Interbranch applicability• Construction industry• Plant construction industry• Machine building industry
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Structure of STS(Simulation Toolkit Shipbuilding)
Steel
BasicsLogistics
Transport
Material
Outfitting Interior fitting
- Space- Model administration- Personnel control- Statistics- ...
- Cutting machines- Welding machines- Assembly sites- Painting facilities- ...
- Storage control- Supplier- Packaging- ...
- Steel parts - Steel elements- Outftting parts- ...
- Floor conveying syst- Cranes- Roller conveyors- Streets / crossings- Transport control
- Outfitting sites- Assembly control- ...
- Compartment- ...
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Structure of STS Including Add-on Libraries (Simulation Toolkit Shipbuilding)
STS_OWEA- Offshore windpark
installation
STS_PortLog
STS_ShipLog
- Container terminals- RoRo terminals- Ferry terminals
- Load and discharge ships
Steel
BasicsLogistics
Transport
Material
Outfitting Interior fitting
- Space- Model administration- Personnel control- Statistics- ...
- Cutting machines- Welding machines- Assembly sites- Painting facilities- ...
- Storage control- Supplier- Packaging- ...
- Steel parts - Steel elements- Outftting parts- ...
- Floor conveying syst- Cranes- Roller conveyors- Streets / crossings- Transport control
- Outfitting sites- Assembly control- ...
- Compartment- ...
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Examples for Tools of STS(Simulation Toolkit Shipbuilding)
Crane
Space
Outfittingcompartment Cutting plant
Stiffenererection portal
Statistics
Transport control
Assemblycontrol
Steel
BasicsLogistics
Transport
Material
Outfitting Interior fitting
- Space- Model administration- Personnel control- Statistics- ...
- Cutting machines- Welding machines- Assembly sites- Painting facilities- ...
- Storage control- Supplier- Packaging- ...
- Steel parts - Steel elements- Outftting parts- ...
- Floor conveying syst- Cranes- Roller conveyors- Streets / crossings- Transport control
- Outfitting sites- Assembly control- ...
- Compartment- ...
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Characteristics of the Tool STS_Crane
Management of transports by cranes of several types (gantry, bridge, container, construction, ...)
� Easy use• Method .request(part, target)• Qualified and available crane vehicle is selected.• Crane motion is generated automatically.
� Option: Specification of individual transports:• Linking of gantries for heavy transports• Turning of parts• Personnel for transport• Definition of transport path• Mobile crane on vehicle• ...
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Different Crane Types ModelledUsing the Tool STS_Crane
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Tool STS_Space for Space Allocation
� Allocation of space by objects considering• Size or geometry (shape)• (Safety) distance required
� Definition of• Areas for special purpose (building site, storage area, ...)• Blocked areas (temporally if necessary)
� Various allocation rules available• Starting point and direction• Circular search• Closest to specific object• Maximum available space• ...
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The Tool STS_ProcessControl
Control of several parallel assemblies considering
� Standardized or individual process patterns
• Selection of worksteps• Sequence of worksteps
� Consideration of part characteristics
� Allocation of required qualifications
� Hard and soft assembly constraints
� Spatial constraints
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SimCoMar: Simulation Cooperation in the Maritime Industries
� Flensburger Schiffbau-GmbH & Co. KG
� Blohm & Voss Nordseewerke GmbH
� Fr. Lürssen Werft
� Howaldtswerke – Deutsche Werft
� Technische Universität Hamburg-Harburg
• IPM - Institut für Produktionsmanagement und –technik
� Technische Universiteit Delft (NL)
� Center of Maritime Technologies e. V.
� ANAST – Universität Liège (B)
www.simcomar.com
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SIMoFIT – Simulation of Outfittingin Shipbuilding and Civil Engineering
� Simulation of Outfit ting Processes in Shipbuilding and Civil Engineering� Cooperation of shipyards and civil engineers� Basis for development: STS (Simulation Toolkit Shipbuilding)� Constraint based simulation: generic definition of constraints
www.simofit.com
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Fields of Activity for Material Flow Simulation at Flensburger
Production Planning
strategicLayout planning
tactical
operative
today time
Logistics
Production Development
Ship Harbour
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Evaluation of Concepts for a New Part Fabrication
• Replacement of old plant (under water)• Cutting and
grinding, marking, signing (both sides)• Throughput at least 1,5 of initial situation
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Simulation of the Part Fabrication
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Development of a New Profile Cutting Line
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SAPP - Simulation Aided Production Planning
todayPlanning horizon
StrategicPlanning
� Definition of suitable flow
� Raw product data
TacticalPlanning
� Verification of monthly plan
� Real product data available
� Raw status needed
OperativeControl
� Realisation of plan and reaction on deviation to plan
� Detailed online status necessary
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Simulation Aided Production Planning (SAPP)
� Verification and improvement of program plan in early planningphase• Feasibility studies• Bottleneck analysis• Analysis of robustness• Improvement by changing building strategies, sequences, ...• Definition of dates and sequences
� Weekly adjustment of plan• Final adjustment of manning level and dates based of production
status
� Reaction on disturbances• Evaluation of strategies to get back to the plan
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Data Flow to Simulation
SimulationmodelSimulation
database
MARSMaterial control
ALMANesting, NC-files
NUPASDesign
Productionstatus
ACOSScheduling
Product data
Personnelplanning
Data periphery
DigiMethBuilding methods
Input data
Output data
SimulationmodelSimulation
database
MARSMaterial control
ALMANesting, NC-files
NUPASDesign
Productionstatus
ACOSScheduling
Product data
Personnelplanning
Data periphery
DigiMethBuilding methods
Input data
Output data
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Presentation of Results inSimulation Database
Estimated deviation of dates plan/simulation
Estimated utilisation of production stations
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Using Simulation for Planning of the Panel Line
Workers
Reduction from 22 to 14 workers
Difference of production to plan [d]
Time of implementation
� Transfer of production strategies from the simulation to the shop floor
� Defining personal by simulation� Scheduling by simulation
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Continuous Validation of the Simulation Results
Diffrence between simulated dates and real production datesin pre-production
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Simulation in the Program Planning of a RoRo-Series
Simulation of production of three ships for program planning10 months ahead of production
Forecasted schedule variance at the beginning of the project
Forecasted schedule variance after using simulation
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SAPP Applications at Flensburger
Profile production
Plate production
Block production
Hull erectionPainting
Logistics
Pre-production
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Planned Plate Storage in Denmark
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Pax-Logistics for BC -Ferries
Concept for handling of additional material building RoPax vessels:� External storage� Shuttle traffic connecting external
storage and shipyard� Buffer sizes and locations at FSG� Size and control of
transporter fleet
Goal:Simulation basedcontrol toolfor logistics
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Simulation Model of the Pre-Production
Platecutting
Platewelding
Profilemounting
Outfittingassembly
Section assembly and
outfitting
Welding profiles and
outfitting
Section welding
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Simulation of Closed Section and Block Assembly
Space allocation Assembling processes
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Simulation Model of Block Assembly
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Simulation Model of Flensburger Shipyard
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Simulation Model of Refurbishment Proceduresin a Passenger Zone
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SIMGO –Simulation Based Optimization
Inputdata
Simulationmodel
Optimisingtool
Optimisedresult
FKZ: 03SX219
Results Parametervariation
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Simulation Based Optimizationin Part Fabrication
Blasting andmarking machine Cutting machine
Bottleneck cutting machine has waiting time� Sequence has impact on throughput
Optimization runs to minimize production time:
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Research Project HEPP – High EfficientProduction Planning for Prototype Competence
� Goals:• Methods to prepare, check and improve the data basis for
planning especially in early project phases• Continuous simulation aided production planning in
shipbuilding
� Term: 01.10.2013 – 30.09.2016� Partners:
• FSG (Coordinator)• Meyer Werft• SimPlan AG• Center of Maritime Technologies e.V.• Ruhr University Bochum• Technical University Hamburg-Harburg
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Simulation of Logistics at Flensburger
Simulation of Loading and DischargingSimulation of
Logistic Chains
Route and fleet simulation
Simulation of Port Logistics
Ferry terminalsRoRo terminals
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Simulation of Discharging and Loading a RoRo Carrier
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Simulation of a Planned Ferry Terminal
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Simulation of Container Terminals
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Simulation of a Container TerminalOperated by Straddle Carriers
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Simulation of an Inland Container Terminal in Berlin
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Simulation Model of the Logistics for Wind Park Installation
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Thank youfor your attention!
Dirk Steinhauer
Head of Simulation Team
Department of Research and Development