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Procedia CIRP 00 (2019) 000–000
Procedia CIRP 00 (2019) 000–000
ScienceDirect www.elsevier.com/locate/procedia
www.elsevier.com/locate/procedia
Procedia CIRP 00 (2017)
Procedia 000–000
CIRP 88 (2020) 122–126
www.elsevier.com/locate/procedia

13th CIRP Conference

13th CIRP Conference on
on Intelligent
Intelligent Computation
Computation in
in Manufacturing Engineering, CIRP
Manufacturing Engineering, CIRP ICME
ICME ˈ19
ˈ19

Method for
Method28th integrated
forCIRP
integrated logistics planning
logisticsMay
Design Conference, planning in
in shipbuilding
2018, Nantes,shipbuilding
France

A new methodologyJan to Sender

Jan analyze
Sender a,
the functional
a,*, Steffen
*, Steffen Klink b
Klinkb,, Wilko
Wilko and physical
Flügge
Flügge
bb
architecture of
existing products
Fraunhofer
a
Fraunhofer
a forfor
Research Institution
Research Institution foran
Largeassembly oriented
Structures in Production
Large Structures in Production product
Engineering IGP,
Engineering IGP, family
Albert-Einstein-Str.
Albert-Einstein-Str. identification
30, 18059
30, 18059
University of Rostock, Chair of Manufacturing Technology, Albert-Einstein-Str. 2, 18059 Rostock
b
Rostock, Germany
Rostock, Germany
University of Rostock, Chair of Manufacturing Technology, Albert-Einstein-Str. 2, 18059 Rostock
b

* Corresponding author. Tel.: +49-381-49682-55; fax: +49-381-49682-12. E-mail address: jan.sender@igp.fraunhofer.de

Paul Stief *, Jean-Yves Dantan, Alain Etienne, Ali Siadat
* Corresponding author. Tel.: +49-381-49682-55; fax: +49-381-49682-12. E-mail address: jan.sender@igp.fraunhofer.de

École Nationale Supérieure d’Arts et Métiers, Arts et Métiers ParisTech, LCFC EA 4495, 4 Rue Augustin Fresnel, Metz 57078, France

Abstract
Abstract
* Corresponding author. Tel.: +33 3 87 37 54 30; E-mail address: paul.stief@ensam.eu
In
In shipbuilding
shipbuilding thethe transport
transport processes
processes are
are of
of major
major concern
concern during
during the
the planning
planning ofof production
production facilities
facilities and
and processes.
processes. Due
Due toto the
the heavy
heavy
weights of the shipbuilding interim products the transport resources and procedures are essential planning topics
weights of the shipbuilding interim products the transport resources and procedures are essential planning topics for shipyards. This paper for shipyards. This paper
describes an approach for an integrated production and logistics planning focusing the particular circumstances of
describes an approach for an integrated production and logistics planning focusing the particular circumstances of the shipbuilding transport the shipbuilding transport
Abstract
processes.
processes. Therefore
Therefore aa logistics
logistics simulation module is
simulation module is introduced
introduced which
which enables
enables the
the integration
integration ofof issues
issues from
from the
the planning
planning ofof logistics
logistics processes
processes
into
into the
the production
production planning
planning of
of shipyards.
shipyards. The
The functionality
functionality of
of the
the approach
approach is
is proven
proven on
on a
a planning
planning example
example for
for a
a shipyard.
shipyard.
In©today’s business environment, theElsevier
trend towards more product variety and customization is unbroken. Due to this development, the need of
© 2019
agile2020
2019 The
andThe
Authors.
Authors.
reconfigurable
Published by
Published
production
by Elsevier
systems
B.V.
B.V.
B.V.
emerged to cope with13th
various products and product families. To designinand optimize production
Peer-review
This is an
Peer-review under
open
under responsibility
access article the
responsibility of
under
of the scientific
CC committee
BY-NC-ND
the scientific of
of the
license
committee CIRP Conference on Intelligent Computation
(http://creativecommons.org/licenses/by-nc-nd/4.0/)
the 13th CIRPmethods
Conference on Intelligent Computation Manufacturing
in known
Manufacturing
systems as
Engineering. well as to choose optimal product matches, product analysis are needed. Indeed, most of the methods aim to
Peer review under the responsibility of the scientific committee of the 13th CIRP Conference on Intelligent Computation in Manufacturing
Engineering.
analyze a product or one product family on the physical level. Different product families, however, may differ largely in terms of the number and
Engineering, 17-19 July 2019, Gulf of Naples, Italy.
nature of components.
Keywords: This fact
Shipyard planning; impedes
Digital an efficient
shipbuilding; Logisticscomparison
simulation and choice of appropriate product family combinations for the production
Keywords:
system. A newShipyard planning; Digital
methodology shipbuilding;
is proposed Logistics
to analyze simulation
existing products in view of their functional and physical architecture. The aim is to cluster
these products in new assembly oriented product families for the optimization of existing assembly lines and the creation of future reconfigurable
assembly systems. Based on Datum Flow Chain, the physical structure of the products is analyzed. Functional subassemblies are identified, and
a1.functional analysis is performed. Moreover, a hybrid functional and physical
Introduction architecture
processes. graph (HyFPAG)
This results
results in unnecessaryis theproduction
unnecessary output which depicts
costs the
caused
1. Introduction
similarity between product families by providing design support to both,processes. production This
system in
planners and product production
designers. costs
An caused
illustrative
by
by waiting times,
waitingcase
times, low resource utilization or missed delivery
example
The of a nail-clipper
shipbuilding is used to
industry hasexplain
to cope
copethewith
proposed
high methodology.
complexity Andates industrial
dates studylow
what reduces
reduces the
resource
on two productutilization
competitivenessfamiliesofof
or missed
thesteering
delivery
columns
shipyard. of
The shipbuilding industry has to with high complexity what
thyssenkrupp Presta France is then carried out to give a first industrial evaluation of the proposed approach. the competitiveness of the shipyard.
within the
the shipbuilding
shipbuilding process.
process. This
This complexity
complexity results
results from
from The maritime
maritime market
market is is highly
highly volatile.
volatile. Fluctuating
Fluctuating demand
demand
©within
2017 The Authors. Published by Elsevier B.V. The
a high complex
a high complex
Peer-review
structure of
structure ofofathe
under responsibility
a ship
ship with a large
with acommittee
scientific
number
large number of
of CIRP
of the 28th
of different
of Design
different ship types
ship types
Conference
influence the strategic
2018.influence the strategic planning of
planning of
different parts
different parts and
and interim
interim products.
products. A A ship
ship assembly
assembly takestakes shipyard facilities
shipyard facilities [2].
[2]. This
This forces
forces shipyards
shipyards to to adapt
adapt their
their
place in a large
place in aAssembly;
Keywords: number of
Design of
large number production
method; stages starting
Family identification
production with
stages starting with steel steel production system continuously to new
production system continuously to new circumstances. circumstances.
parts and outfitting components and ending with
parts and outfitting components and ending with the final ship. the final ship. Changes in
Changes in one
one production
production stage
stage have
have aa high
high impact
impact onon the
the
Between the
Between the production
production stages
stages are
are aa lot
lot interdependencies
interdependencies as as up- and downstream processes
up- and downstream processes due to the high due to the high
well as a high degree of parallelization to keep
well as a high degree of parallelization to keep the execution the execution interdependencies between
interdependencies between thethe production
production stages.
stages. Thus,
Thus, anan
1.time
Introduction
as short
short as as possible.
possible. Shipyard
Shipyard deploy deploy specialized
specialized of the product
isolated range andofcharacteristics
consideration adjustments manufactured
on a and/or
resource is
time as isolated consideration of adjustments on a resource is
resources to built ships. Beside shipbuilding specific assembled in this system. In this context, the main challenge in
inappropriate.
resources to built ships. Beside shipbuilding specific inappropriate.
Due to facilities
production the fast(e.g. development
panel assemblyin the domain
lines, drydocks) of modelling and analysis is now not only to cope with single
production facilities (e.g. panel assembly lines, drydocks)
communication
transport systems andas an
largeongoing
goliath trend
cranes ofcharacterize
digitizationtodays and products, a limited product range or existing product families,
transport systems as large goliath cranes characterize todays
digitalization,
shipbuilding manufacturing
process. Especially enterprises
Especially thearehigher
in the facing production
higher important but also to be able to analyze and to compare products to define
shipbuilding process. in production
challenges
stages in today’s
shipyards have market
to handleenvironments:
large and a continuing
heavy interim new product families. It can be observed that classical existing
stages shipyards have to handle large and heavy interim
tendency towards reduction ofmodules).
product development times and product families are regrouped in function of clients or features.
products (e.g. units, blocks, modules). [1] Figure 1 shows aa
products (e.g. units, blocks, [1] Figure 1 shows
shortened product lifecycles. In addition, there is an increasing However, assembly oriented product families are hardly to find.
typical arrangements of cranes in a final assembly hall of aa
typical arrangements of cranes in a final assembly hall of
demand
shipyard. of customization, being at the same time in a global On the product family level, products differ mainly in two
shipyard.
competition
To ensure with competitors
an efficient
efficient all over theshipbuilding
and competitive
competitive world. Thisprocesstrend, main characteristics: (i) the number of components and (ii) the
To ensure an and shipbuilding process
which
it is is inducing
necessary to the development
synchronize all fromresources
shipyard macro according
to micro type of components (e.g. mechanical, electrical, electronical).
it is necessary to synchronize all shipyard resources according
markets,
to the results inprogram.
the production
production diminished By an lotinsufficient
an sizes due synchronization
to augmenting Classical methodologies considering mainly single products
to program. By insufficient synchronization
product
of the varieties
resources (high-volume
the shipyardto low-volume
loses production)
efficiencies in [1].
the or solitary, already existing product families analyze the
of the resources the shipyard loses efficiencies in the
To cope with this augmenting variety as well as to be able to product structure on aarrangement
Fig. 1. Crane
Fig. 1. Crane physical level
arrangement (components
in shipyard
in shipyard level) which
final assembly.
final assembly.
identify possible optimization potentials in the existing causes difficulties regarding an efficient definition and
2212-8271 ©system,
production 2019 The Authors. Publishedtobyhave
Elsevier B.V. knowledge
2212-8271 © 2019 The it is important
Authors. Published by Elseviera precise
B.V. comparison of different product families. Addressing this
Peer-review
2212-8271 ©under
2020responsibility
The Authors. of Published
the scientific
bycommittee of the 13th CIRP Conference on Intelligent Computation in Manufacturing Engineering.
Elsevier B.V.
Peer-review under responsibility of the scientific committee of the 13th CIRP Conference on Intelligent Computation in Manufacturing Engineering.
This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/)
Peer review
2212-8271 under
© 2017 the
The responsibility
Authors. Publishedofbythe scientific
Elsevier B.V.committee of the 13th CIRP Conference on Intelligent Computation in Manufacturing
Engineering,
Peer-review 17-19
under July 2019,ofGulf
responsibility of Naples,
the scientific Italy. of the 28th CIRP Design Conference 2018.
committee
10.1016/j.procir.2020.05.022
 Jan Sender et al. / Procedia CIRP 88 (2020) 122–126 123
J. Sender et al. / Procedia CIRP 00 (2019) 000–000

To deal with these dynamic interdependencies within

production processes it is common to apply simulation-based
planning tools. These tools often implement the discrete event
simulation approach. It is well-suited for this kind of planning
issues as it is able to consider the dynamic behavior of a
complex systems with many interdependencies and parallel
processes. [3]
This paper introduces an approach for the integrated
logistics planning within the shipyard planning process. A
simulation tool is presented, which enables to regard shipyard
specific logistic process in a factory design environment.

2. Integrated logistics in production planning

Fig. 2. Results of a simulation study [4].
To design production facilities production planner use
modern simulation tools to support the decision-making In shipbuilding another planning approach is a separated
process for different planning tasks. Typical planning tasks in consideration of production and logistics. In the first step the
the maritime industry are: production simulation model calculates delivery dates as well
as sources and sinks for transport processes for each
 Layout planning and evaluation of investments production stage. The information of the production
 Reorganization of production structure and/or processes simulation model used as input data for the second step, the
 Performance and productivity analysis transport simulation. The transport simulation only considers
 Make-or-buy analysis the transport process and resources. The aim of this
 Evaluation of producibility of new orders simulation is to find a configuration of transport resources to
meet the transport demand of the production simulation
By performing simulation studies for the planning tasks the model. An integrated planning is not part of this approach.
simulation tools generate key figure that characterize the [14]
performance of the production system for a certain simulation The research approaches performing an integrated
run. The most important key figures of simulation studies for consideration consider especially the crane resources. The
the planner are: implementation of crane models in the simulation systems
enable to simulate certain crane activities. Exemplarily
 Utilization of production resources (machines, personnel, activities are:
transport systems, area) for identification of bottlenecks
and productivity potentials  Turning parts with the crane during transport process [15]
 Throughput times of parts  Coupling of different cranes to increase transport capacity
 Delivery dates of ships in comparison to the proposed [16]
delivery date of a ship
 Generated production costs for different orders Other simulation approaches only consider the transport
itself but in a very detailed way. The tool calculates forces in
Fig. 2 shows an exemplarily result for key figures of wire ropes as well as the dynamic behavior of the structures.
shipbuilding network evaluation [4]. As the variation of the The collision detection between transport part and transport
planning tasks is very high, the focus of scientific work in the resource is another aim of these tools. They are used for the
simulation-based planning in shipbuilding also shows a wide detailed planning of complex transport maneuvers. [17, 18,
range in the application. Most application show a focus on the 19, 20]
consideration of production facilities as they in general In other industries integrated logistics approaches are also
represent the highest investment within a planning project. In gaining an importance. Some approaches show the advantage
these cases, the transport processes are often regarded as of an integrated planning approach taking the example of an
sequential processes (e.g. [5, 6, 7, 8]). So the transport integrated scheduling [21, 22, 23, 24]. Further examples focus
processes are modelled in a simplified way. In these on integrated logistics approach for supply chain applications
approaches often only certain workshops or processes of a [25, 26, 27].
shipyard a considered in the planning application [9, 10, 11, The analysis of current work on integration of logistics into
12, 13]. The problem is, that this kind of modelling is only production planning shows the benefits of an integrated
sufficient for throughput time analysis. But when it comes to approach for production facilities and logistics as well as first
bottlenecks within the transport resources the simplified good approaches for shipbuilding applications.
modelling could lead to wrong key figures. As a result, the Nevertheless, a planning approach is missing to implement
planner could make wrong decisions based on these key the integrated logistics planning in the shipyard planning
figures. process by considering shipyard specific transport processes.
124 Jan Sender et al. / Procedia CIRP 88 (2020) 122–126
J. Sender et al. / Procedia CIRP 00 (2019) 000–000

Here it is required to incorporate the logistics process into the

production-planning tool. Therefore, the next chapter explains
the shipbuilding specific transport processes and shows the
process models as a basis for implementation into a
production simulation model.

3. Modelling logistics in shipbuilding

Transport processes connect the resources of the

production stages and fulfill the shipyards material flow. The
large dimensions and weight of shipbuilding interim products
make special transport systems necessary. Thus, the transport
systems of a shipyard are accompanied with a high
investment. Consequently, the shipyard planner should
consider the transport processes within the shipyard planning
with major concern. Andritos & Perez-Prat give an overview
Fig. 3. Process of overlapping production and logistics resources.
on typical shipbuilding transport resources and their transport
capacity range. [28]
This process is quite difficult as an exact position is
Beside the high investment the transport resources are
required for safe transport of the unit. In the next step the
often a bottleneck during the shipbuilding process. They are
heavy load transporter fulfills the transfer of the unit to the
relevant to the shipbuilding lead time and embody a strategic
next production hall, the block assembly. In the block
resource for a shipyard. These transport resources should be
assembly the heavy load transporter moves to the transfer
integrated into the production planning process in an adequate
station. Then the crane in this production hall fastens the unit.
manner. To integrate the transport systems into the planning
When the unit is fastened the crane unloads the unit from the
process it is essential to understand the logistic processes on a
heavy load transporter. The crane positions the unit on the
shipyard. In the following two shipbuilding specific process,
desired area in the assembly. Figure 4 shows the combined
which need to be regarded, are explained exemplarily.
transport with the parallel occupation of transport resources.
Some shipyards deploy special racks on the transfer station to
3.1. Overlapping usage of transport and production resources
decouple the crane from the heavy load transporter. In
practice a combination of this two transport types take place
The use of crane resources during assembly is very
to fulfill the overall transport process of unit to the block
common in shipbuilding. In the block assembly blocks are
assembly. The described processes are transferable to other
assembled from units. And in the final assembly the ship is
transports of a shipyard. For example:
assembled from blocks. Both assembly is done by crane
usage. The following explanation focusses on the block
 Outfitting modules from outfitting to block assembly
assembly process but it is the same procedure in the final
 Main Engine from delivery to final assembly
assembly. The crane transports the unit to the block assembly
 Unit from unit assembly to blasting and painting
area. Then the unit is positioned by crane. After exact
positioning the unit is tack-welded to the already assembled
unit of the block. During this tack welding the crane has to
hold the weight of unit. The crane is occupied for the holding
process until the welding seam is proper to hold the weight of
the unit and there is no risk for a drop down of the unit. After
the holding time the crane is available for the next transport
process. Figure 3 shows the process in a swim-lane diagram.

3.2. Combined transport with overlapping transport resources

When a shipyard operates in different production halls a

combined transport is necessary to realize a transport from
one production hall to another. For large scale part as units or
blocks each production hall possesses a transfer station.
According to paragraph 3.1 the following explanation focuses
on a unit transport to the block assembly. A crane transports
the assembled unit from the assembly area to the transfer
station. At the transfer station the crane positions the unit onto
a heavy load transporter. Fig. 4. Process of overlapping logistics resources.
 Jan Sender et al. / Procedia CIRP 88 (2020) 122–126 125
J. Sender et al. / Procedia CIRP 00 (2019) 000–000

The process models are a good basis to implement them to The simulation run points whether there is a bottleneck in a
a shipyard production simulation model. The implementation production or a logistics facility. The presented simulation
enables to accomplish an integrated production and logistics tool is called YardPlan 2.0 and is used in shipyard planning
planning system. projects around the globe. Figure 5 shows the structure of
YardPlan 2.0. The figure highlights the transport module in
4. Implementation in shipyard simulation tool black.

For an existing shipyard production simulation model [4] a 5. Use case

new transport planning module is introduced. The transport
planning module is integrated to the resource structure of the To verify the simulation to this chapter describes a
shipyard resource model. Each transport resource has specific shipyard planning use case. The goal of the planning task to
characteristics as for example: find a resource configuration for an existing shipyard to
realize a production program of four containerships per year.
 Capacity The lead time per ship should not exceed 9 month. Therefore
 Speed the shipyard planner has to define an investment program
 Possibility to combine with other transport resources suitable for this task.
 Range of motion The first step is to model the shipyard with the resources
within the simulation tool. The resources include the
With this data it is possible to verify if the transport production as well as transport systems with their
resource is able to fulfill a transport request from a part with a characteristics. Then the planner defines the product model
specific weight, a source station and a sink station. In case for the container ships with the product structure as well as
that there is no transport resource able to reach source and the work plans for the parts.
sink a combination of resources takes place. An Algorithm is In the next step the first simulation run takes place and
implemented to perform this combination. The algorithm points out the bottleneck of the shipyard. Then the planner
check routes of possible transport resources from source to eliminates the bottleneck by simulation an investment and
sink by checking the capacity for each transport resource on increasing the capacity. For the first simulation run it is the
the route as well as the possibility to combine the resources. panel line of the shipyard. After implementing a new panel
In case that the algorithm finds out more than one line, the next simulation run is performed. Now the bottleneck
combination of transport resource, the combination with the changes to the painting process. In the following simulation
shortest and fastest track is defined to fulfill the transport. run the planner increase painting capacity by investing in new
The next step is the extension of the work plan of the units painting facilities. In the third simulation run the block
and blocks with the information for required holding times. assembly is the bottleneck. The analysis of the simulation data
With this information the unit is able to request a transport enables the planner to check which resource has the highest
resource not only for a transport but for holding procedures utilization. Here the crane has the highest utilization. Thus not
during the assembly process. This integration of the logistics a new block assembly area is required but an additional crane.
module enables the shipyard planner to perform most of the Figure 6 shows the results of this iterative simulation
planning task in one simulation tool. All relevant resources procedure. The upper array points out the investment needed
and processes are modeled and implemented to perform a to reach the planning goals.
simulation run for the entire shipyard.

Fig. 5. YardPlan 2.0 planning tool. Fig. 6. Results from iterative planning procedure for the use case.
126 Jan Sender et al. / Procedia CIRP 88 (2020) 122–126
J. Sender et al. / Procedia CIRP 00 (2019) 000–000

4. Conclusion [14] Wang C, Mao YS, Xiang ZQ, Zhou YQ. Ship Block Logistics
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