2001 Korea-Japan CAD/CAM Workshop
IT for 21C Shipbuilding Industry
- CAD/CAM & IT Trends in Shipbuilding -
July 12, 2001
DAEWOO SHIPBUILDING & MARINE ENGINEERING CO., LTD
DSME Okpo Shipyard
Yard Facilities
• Site Area
: 4,206,000 ㎡
• Covered Shop :
351,000 ㎡
• Outfitting Quays :
3,198 m
• Docks : 2 Dry Docks(530X131X900T,
350X81X450T) &
3 Floating Docks
Annual Production Capacity
Commercial Ships
35 ~ 45 vessels
Offshore Structures
2 ~ 4 projects
Plants / Steel Struct. 25 ~ 30 plants
Special Ships
1 submarine & 4 frigates
- Number of Employees : 11,000
DAEWOO Shipbuilding & Marine Engineering
Major Products of DSME (1) - Commercial Ships
COT (Crude Oil Tanker), VLCC
LNGC (LNG Carrier)
ROPAX(RORO Passenger Ship)
RORO (Vehicle Carrier)
Container Carrier
DAEWOO Shipbuilding & Marine Engineering
Major Products of DSME (2) - Offshores/Plants/Special Ships
Plant (Gas Compression Platform)
Drilling Rig, Semi-submersible
FPSO
(Floating Production Storage
and Offloading)
Frigate
Submarine
DAEWOO Shipbuilding & Marine Engineering
Today of Korean Shipbuilding Industry

World widely No.1 in Market Share : 45% (2000)

Very Competitive in Cost & Productivity and Reasonably in Quality & Tech.

Flexible Technology & Design Capability based on Large Engineering
Manpower Resource

Rapid Increase in Productivity by Implementing CAD/CAM & Other IT
for last 10 Years but Currently Slow Down

Transition from Conventional Commercial Ships to High-Value Ships &
Offshores
- LNG Carriers
- Super-Size Container Carrier
- High Speed Ships
- FPSO
- Passenger Ships
- Rig / SPAR / TLP & Other Offshores
DAEWOO Shipbuilding & Marine Engineering
IT for Shipbuilding Industry
• IT is the key technology to maintain the shipbuilding business competitive.
“ a key tool for the competitiveness” - T. Koyama
“ a weapon, providing competition advantage” - A. Dallas
• Innovation of information/process flow and data management is essential
for the competitiveness of 21C shipbuilding business.
Shipyards
 Product Model & Parametric Based
Advanced CAD
CAD/System Vendor
 Product Data Management & DBMS
Suppliers
 Integration of CAD/CAM & Production
Automation : Shipbuilding CIM
Class, Government/Navy
 Information Share & Exchange :
Ship CALS, Virtual Shipyard, WEB
DAEWOO Shipbuilding & Marine Engineering
Change of Shipbuilding Business Environment

Ship Owner’s Requirement
– low cost but high performance & quality
• faster, safer and better capacity

Mostly New Designs for each Order with Short Construction Period
– concurrent and collaborative design & manufacturing
– speed game, importance of time & schedule management

More Accurate & High Quality Information/Data Needed
– increased design & engineering information
– more and more details, multiple cycles of design spiral

Solution
– Integration of information using IT for :
• Increasing the Accuracy and on-Timing of Planning
• Engineering for Production
• Integration of CAD(Hull & Outfitting)/CAE/CAM/Production
DAEWOO Shipbuilding & Marine Engineering
Barriers in Shipbuilding IT to Be Overcome
- Characteristics of Shipbuilding Practice
– Mostly New Design for Each Order (Tailor-Made)
• 15 - 20 New Design Developments per Year
• Management of about 10 Different Products at the Same Time (Product-Mix)
– Fabrication of Large Assemblies & Heavy Machineries
• Uncountable Design & Production Processes, Steps and Activities
• Large Number of Manpower, Organizations and Systems
– Number of Parts : Size of Data or Objects
• 105 (Ships) - 106 (FPSO, LNG, Plant) for each Product
• [cf] Automobile : 20,000 Airplane : 105 - 106
– Short Period of Design & Engineering for a New Product
• 8-9 Months for each Ship
• Concurrent Information Generation and Changes and Several Design Spirals within
a Given Short Period. Needs for Management of Huge Size Data
– Small Size of Shipbuilding IT Market
• 3,500 CAD Seats(Korea), Less Than 20,000 CAD Seats(Worldwide)
– Others : Large Scale & Complicated System Solutions (Integration & Interface),
Complex Geometric Shape of Ships (Limited Space)
DAEWOO Shipbuilding & Marine Engineering
Ship Models : Hull-Form & Compartment Surface Models
DAEWOO Shipbuilding & Marine Engineering
Ship Models : Hull Structures
Aft - Body
Fore - Body
DAEWOO Shipbuilding & Marine Engineering
Ship Models : Outfitting(Seat/Pipe/Traffic/Handrail) Models
모델
Engine Room Deck
DAEWOO Shipbuilding & Marine Engineering
Key Technologies & Infra for Shipbuilding IT
Infra / Resources
Core Software Technologies
• Human Factor (Attitude &
• Parametric CAD
Understanding to New Tech. & Culture)
• WEB
• GUI
• Standardization
• DBMS
• BPR
• OOP
• Software Performance
• Feature Based Modeling
• Network Performance
• Hardware Capability
• PDM
• Information Modeling
• Visualization, VR
• Distributed Object Computing
• Data Exchange : STEP, IGES...
DAEWOO Shipbuilding & Marine Engineering
IT Development Trends in Shipbuilding
* [PTC Data]
Benefit
As below +
Simulation Based Engineering
Supplier Integration (B2B)
Through Life Information Mgt
Cost Management
Network
Intelligent Product Model Capacity
Advanced Visualization(VR)
Wall
Engineering Data Management
BoM to MRPII
Concurrent Engineering
World Class Shipyards
Power
Wall
Digital Prototype
Engineering Data Management
Concurrent Engineering
Shared Data Environment
Full 3D Model
Leading European, Asian
Visualization
and most US Shipyards
Point to Point Integration
Functional Organisation
Mainly 2D, Some 3D
Non Integrated Systems
Some European, Asian
and US Shipyards
2D Draughting
Non Integrated Systems
DAEWOO Shipbuilding & Marine Engineering
Worldwide IT Projects in Shipbuilding
MARITIME
ESPRIT
MARVEL
EMSA
Etc.
CIMS
CALS
GPME
JOHAKU
Etc.
NSRP
MARITECH
COMPASS
MariSTEP
Etc.
CSDP
CIM Project
CAD Develop.
CALS
DAEWOO Shipbuilding & Marine Engineering
Change of Shipbuilding IT Concept and Approach








from Computer Aided Drafting to Computer Aided Design
from Yard Standard to Industry(International) Standard
from Engineering for Design to Engineering for Production
from Sequential to Parallel(Concurrent)
from Individual to Collaboration
from Geometry Model to Product Model
– Product Life Cycle Support
to component software building
to multi-tier application development
DAEWOO Shipbuilding & Marine Engineering
IT Development History in Korean Shipbuilding
PROJECT
PERIOD
CONTENTS
1970s

MIS, NC, …
1980s

2D CAD for Drafting

CSDP
1st half 1990s

3D CAD/CAM for Production

CIM Project 2nd half 1990s

CIM
– Information Integration
– Advanced CAD Development

Shipbuilding 2000s
CALS

CALS/EC
– e-Business
DAEWOO Shipbuilding & Marine Engineering
Completed IT Projects in Korean Shipbuilding
CSDP
CIM-Project


Computerized Ship Design &
Production
CIM Project for Shipbuilding
– 3D Product Modeling
– Production Planning &
Simulation
– DBMS, Expert Systems, etc
– Basic Technology Research
– Engineering Applications
– Optimization Technique, etc

1st half of 1990s

2nd half of 1990s

Consortium

Consortium
– KRISO
– 4 Major Shipbuilders
• DSME, HHI
SHI, HANJIN
– KRISO
– 4 Major Shipbuilders
• DSME, HHI
SHI, HANJIN
DAEWOO Shipbuilding & Marine Engineering
On-Going Projects in Korean Shipbuilding
Shipbuilding CALS
e-Market Place


Collaborations for e-Procurement
of Shipbuilding

2001 - on-Going

Consortium
Building Infrastructure for
e-Business of Shipbuilding
–
–
–
–
Electronic Approval
Drawing Exchange
3D Equipment Lib.
e-Catalog …

2001 - 2004 (3 Year Project)

Consortium
– IT Consultants/Companies
– 4 Major Shipbuilders
• DSME, HHI
SHI, HANJIN
– IT Consultants/Companies
– 4 Major Shipbuilders
DAEWOO Shipbuilding & Marine Engineering
DSME CAD Development & Unification Project
- Cooperation with TBS (TRIBON)

Project Scope and Concept
•
•
•
•
•

Develop integrated system from design to production
Develop optimized solution with verified shipbuilding CAD system
Joint development with commercial CAD developing company(TBS)
TRIBON Mx Series based CAD on Windows environment
Concentrated on the development of Open and Flexible Tribon System
Implementation Time Schedule
• M2 : 2002, Q2 = Step 1 items (70 items)
• M3 : 2003, Q3 = Step 2/3 items (64 items)

APIs(VITESSE) Development
• High Priority for DSME Specific Development Items
• Main Area : Draft, Utilities, Pipe, Cable, Structure, Hull Applications
DAEWOO Shipbuilding & Marine Engineering
Current DSME CAD Environments
- Purchasing/Procurement Info.
- Review BOM Information
Hull
Hull DB
TRIBON
Procurement
Limited information sharing
Outfitting
Outfitting DB
Production
CADDS5
Problems
- Production/Scheduling Info.
- Review Design Information
• Design information sharing between Hull & Outfitting
• Difficult to give production information at real time
DAEWOO Shipbuilding & Marine Engineering
After CAD Unification Environments
Integrated DB
Procurement
Hull
Share the Design
Information
Real time Information
Sharing Available
Effects
Production
Outfitting
• Improve information sharing between hull & outfitting at real time
▶ Improve design quality and reduce design time
• Manage the design and production data in integrated DB
▶ Effective support of production/procurement information
▶ Support the information in flexible manner
DAEWOO Shipbuilding & Marine Engineering
Comparison of Two Typical Shipbuilding CAD
Development Strategies
Shipbuilding CAD based Systems
•Old but proven in the shipyard
Theory/Concept •Slow/Low performance but stable
•Non-parametric solution
General CAD based Systems
•New but not proven(no reference)
•High performance but sometimes unstable
•Associative/parametric solution
•Domain specific but easy of use/learn
•Familiar commands
•Worldwide but hard to use directly as-is
•Unfamiliar commands
•Closed
•Light/Compact(no B-rep, no CSG)
•File/Sequential & RDB
•Own Data Format
•Open
•General but Huge/Complex
•Commercial(RDB, OODB…)
•Industrial(International) Standard
Focus
•Drawing/Production data extraction
•Design/Modeling/CAM data
Porting
•Hard
•Easy
•Little, hard to integrate
•Batch style interface
•Many
•Integration(plug in style)
•Little APIs(hard to develop)
•Many APIs(easy of further develop)
•Hard
•Easy
Usability
Data Structure
3rd Party
Applications
API
Automation
DAEWOO Shipbuilding & Marine Engineering
Development of Ship Product Modeling Technology
for Concurrent Engineering
Compartment
Structure
Design
• Nesting
• Drawing
• NC data generation
• etc
Hull Surface
Scheduling
Product Model
BOM
Equip.
Detail Design
Automation
FEA Model
Structure
Model
DAEWOO Shipbuilding & Marine Engineering
What is the Ship Product Model ?

Shipbuilder’s View
– CAD model(or data/information) based engineering model for design
and production
• Including CAE/CAM models and various types of BOM
– legacy data/applications porting and using
– related standardization activities in ISO :
• STEP AP215, 216, 218, 226 and 227

Ship Owner or Operator’s View
– engineering model for ship operating and maintenance
– related standardization activities in ISO : STEP AP233

etc…
DAEWOO Shipbuilding & Marine Engineering
Challenging Problems for Ship Product Modeling

How to maintain integrity of the information
– Optimum level of associativeness for design and information modeling
– reduce the information conflict between different disciplines

How to support domain specific knowledge & in-house applications
– APIs supporting design, engineering and manufacturing processes
– flexibility for the change of IT

How to convert or reuse the legacy data

How to make it easy, simple and light to use
– familiar commands & interface, batch operation for tedious job
– effective data structure storing huge size model
– flexible data structure supporting user attributes(parameters)

Product Model Configuration Management Supporting Multiple
Orthogonal Views
DAEWOO Shipbuilding & Marine Engineering
Examples of the Manufacturing Information
Extracted from the Plant Product Model
pipe piece drawing
beam piece drawing
assembly & BOM
different CAD interface
plate piece drawing
report
DAEWOO Shipbuilding & Marine Engineering
1
Integrated Production Planning System
• Optimized Production Planning Systems
- Lon-Term, Mid-Term, Monthly, Week & Daily
- “What if” Simulation, Reactive Scheduling
- Minimize Work in Process & Duration
Long Term Business Planning
• JIT System of Material Flow
• Personnel & Resource Planning
• Automatic Assembly Block Nesting
Monthly Scheduling
Mid Term Scheduling
Weekly/Daily Scheduling
Design
Logistics
Barchart Schedule
Scheduling
Process
•Dock Planning
•Erection Scheduling
•Pre Erection,
•Block Painting
•Shop Assemble,
•Dock/Quay Outfitting
•Quay Arrangement
DBMS
Optimization Engine [ILOG]
Solve Constraints Satisfaction Problems
Erection Network
DAEWOO Shipbuilding & Marine Engineering
CAM in Shipbuilding
CAD data
• CAD/CAM Integrated Welding Robot
Simulation on 3D Model
&
Off-Line teaching
• Automated Cutting & Marking System
• Automated Nesting System
• Automated Curved Structure
Manufacturing System
- 3-D Block Measuring & Erection Simulation
- Automated Line Heating for Forming
- Auto Pin Jig Information for Curved Block
• Etc
Shop
Working Program
Up/Down Load
DAEWOO Shipbuilding & Marine Engineering
Example of CAM Application Development : Auto Nesting

NC Data Generation

Plate Auto Nesting
– Optimization under Constraints
– Automatic Drawing Generation

Stiffener Nesting
–
–
–
–
–
–
–
–
–
Parametric Geometry Solver
Auto/Semi-auto Nesting
Tool Path Minimization
Automatic Drawing Generation
Drawing Touch Up
Managed by Database System
Web-based
Design Error Check
Component Programming Tech.
DAEWOO Shipbuilding & Marine Engineering
Digital Shipbuilding in Production
• Implement Digital Shop/Shipyard Concept
- Product-Process-Resource Model
- Product Lifecycle Management
- Minimize risk of failure or delay
Scheduling
Logistics
Process
DBMS
• Simulation Based Manufacturing
- Shop Layout Simulation & Process Analysis
- Pre Examination of Alternatives
Design
CAD Interface Sys.
User Define
Process
Information
Scheduling Sys.
3-D Shop Simulator
• Block Location Monitoring System
• Etc.
What if
Senario
Real Time
Fabrication
Information
Product Model
Process Model
Resource Model
Process Monitoring Sys.
Digital Shop
DAEWOO Shipbuilding & Marine Engineering
Future Concerns

Completing and supporting product modeling technology
– Simplified & automated modeling procedure
– Completion of integration
• hull & outfitting
• in-house applications
• with database
– Increasing design & engineering capability
– CAE interface
• Not only mesh, but also loading and boundary conditions
– Supporting multiple orthogonal views

Design/engineering collaboration on the web & PDM

Simulation Based Design & Production Planning
DAEWOO Shipbuilding & Marine Engineering
Development of Effective Concepts :
Simplified Ship Structure Modeling

More than 80% of the ship structures are placed on the planar surface.
– webs and frames, bulkheads, stringers, decks, ...

Such a planar structure is represented as symbolic curve or bounded plane
with attributes(structural drawing itself)
• (ex) using 2D make 3D if necessary
s
200X12 fb
w
drawing for initial design
(arrangement, size, material, …)
Converting knowledge
3D model for production
(real geometric image)
DAEWOO Shipbuilding & Marine Engineering
Example of Integrated Engineering Applications :
Web-based DB for Hull & Basic Designs

Hull Form Design
–
–
–
–
–

Basic Design
–
–
–
–

Geometry
Power Estimation
Resistance
Sea Trial
Design History
Main Dimension
Weight Estimation
Cost Estimation
…
Easy Access & Control
(WEB Technology)
DAEWOO Shipbuilding & Marine Engineering
Example of Integrated Engineering Applications :
Geometry & DB Integrated Propeller Design System

Blade Geometry
Design (Solid)
– Parametic





Wake Analysis
Cavitation Analysis
Power Prediction
Reporting
Propeller Series
Management
– Database
Example of solely integrated propeller design & analysis applications
DAEWOO Shipbuilding & Marine Engineering
Example of Integrated Engineering Applications :
Ship Basic Planning

Volume Definition
 Loading Calculation
 Stability Calculation
– Intact
– Damage





Hydrostatic
Calculation
Longitudinal Strength
Rules & Regulations
Check
Reporting
...
DAEWOO Shipbuilding & Marine Engineering
CAD/CAE Interface Applications

Automatic FE mesh generation from the product model for
– hydrodynamic analysis
– noise & vibration analysis
– structural analysis

Based on
– the hull surface(surface) model
– the subdivision(surface) model
– and structure(3D solid, fatigue analysis) model
DAEWOO Shipbuilding & Marine Engineering
Example of the FE Meshes Generated from the Model
FPSO Flare Tower for Fatigue
Analysis
Solid FE Model
for Fatigue Analysis
FPSO Aft Body
Meshes for Structure
Analysis
Whole Ship
Structural Model
from CAD Surface Model
(LNG Carrier)
DAEWOO Shipbuilding & Marine Engineering
PDM in Shipbuilding
Database
Query
(Marketing)
(Production)
• PC
• Workstation
(Vendor/Class/Owner)
Physical
Databases
Project Access
Information
Tracking
(Design)
Web
Server
Information
Viewing
PDM
Server
Project Information
Spec, Key-Plan, Document,
CAD, Engineering Report
Inquiry, BOM, Vendor...
Auto-Transfer
• Data/Process/Work Flow
• Product Tree
• CAD/OA Connection
DAEWOO Shipbuilding & Marine Engineering
Setup of PDM Environment for Shipbuilding
Marketing
& Design
Word Processor
Inquiry, Estimation
Engineering
Analysis
SPEC
CAD
Product Model
Model
BOMs, Drawings
Owner
Class
Vendor
Electronic Drawing
Control
Meta-database
Other Applications
”DIGITAL DATA"
0
1 1 0 101
File Sorage
PDM System
Word Processor File
FEA File
CAD File
Etc. Digital File
DAEWOO Shipbuilding & Marine Engineering
Product Data Exchange by STEP
STEP file
• Geometry & design data
• SEASPRITETM translator
based on the shipbuilding
STEP AP218 ARM subset



Savings time and cost to exchange
of design & production data
Opportunity to extend electronic
data exchange into a production
environment
Providing faster and more
efficient services to business
partner
DAEWOO Shipbuilding & Marine Engineering
Examples of Design Review through Visualization
Tension Leg Platform(TLP) Detail Design
LPG-FPSO Concept Design
DAEWOO Shipbuilding & Marine Engineering
Example of Plant Visualization :
Incineration Plant
Grate
Control Room
Bag Filter
DAEWOO Shipbuilding & Marine Engineering
Conclusion : IT Development & Application for...
• Implementation of Product Modeling Technology : Concurrent Engineering
• CAD Unification and Development of Features of Next Generation CAD
• Application of New Technologies : Web-based, Parametric, Component, VR...
• Integration of CAD/CAM & Production Systems : Shipbuilding CIM
• Establishment of Information Share & Management Infra : PDM, ERP
• Electronic Business : CALS, e-Marketplace
• Increase of Productivity 30% by IT Innovation
• Realizing the 21C Digital & Virtual Shipyard
DAEWOO Shipbuilding & Marine Engineering