Abstract
In the early 2010s, with rising oil prices and increasing purchase orders for offshore structures for deep-sea resource development, the shipyards that took these orders suffered unexpected losses. Unlike the construction of commercial carrier vessels, the construction of offshore structures necessary to develop deep-sea resources is difficult to manage due to the complexity of the outfitting process of the topside structure, which is a plant for gas and oil production and treatment. Piping components in particular, which comprise most of the design items, are difficult to manage because they involve 2 to 3 times the man-hours and up to 10 times the quantity of items compared to commercial carrier vessels. Due to not only high man-hours and quantity but also large fluctuations caused by design changes and long procurement lead times, process delays that result in delayed compensation frequently occurred. In response, Samsung Heavy Industries developed an integrated management system for piping components. This study describes the entering order optimization algorithm and work-volume assignment optimization algorithm, which are the core algorithms of this system. The entering order optimization algorithm determines the optimal installation order considering the procurement status of the piping components and the installation readiness status of the installation work site, through which it determines the entering order of the piping components. The algorithm seeks to accelerate the completion rate of installation of the piping components. Next, to minimize delivery delays of sub-contractors to the shipyard, this study developed a work-volume assignment optimization algorithm that can equalize the load on multiple sub-contractors considering the raw material readiness status and the production capacity of the sub-contractors, in terms of materials that must be ordered from external sub-contractors among the piping components whose entering order was determined. Finally, applying the algorithm developed using actual shipyard data resulted in an accelerated completion rate of installation and improved balance of load in terms of volume assigned to the sub-contractors.
Highlights
With the increasing deep-sea development of energy resources for oil and gas, the role of shipyards in charge of drilling vessel and floating platform construction are becoming more important1
To verify the effectiveness of the entering order optimization algorithm and work-volume assignment optimization algorithm presented above, the algorithms were applied to a case study using actual shipyard data
The piping components needed to manufacture the topside structure of offshore structures require 2 to 3 times the man-hours and 5 to 10 times the quantity of items compared to commercial carrier vessels, creating limitations in existing management methods
Summary
With the increasing deep-sea development of energy resources for oil and gas, the role of shipyards in charge of drilling vessel and floating platform construction are becoming more important. The field survey results were analyzed using an analytical hierarchy process (AHP), and the order was determined using a computer-aided design model They analyzed the work relationship from production to installation and developed a lead time prediction algorithm. By defining the outfitting material supply problem as a complex vehicle routing problem, they considered the constraints on capacity and various manufacturing sites They optimized material assignment using a multi-population genetic algorithm (MPGA) and improved delivery compliance by 71% in comparison to the existing dispatching rules. Their model improved compliance with a delivery date by 68% in comparison to entering the product based on the delivery date These studies about procurement between companies can be said to be researches about defining a mathematical model and deriving an optimal solution in consideration of the required quantity and characteristics of the sub-contractor. Since the test process (the last process in the p3 ipTinhge ScHoIminpteognraetendt minasntaaglelmateinotns)ysttaemkefsorthpiepilnogncgomesptoanmenotsuwnats odefvteilmopee,dtohnethheigopheerrattinhgesiynstsetmalWlaitnidoonwrsaSteervoefr the2c0o16n(tvinerusiooun s1l8y03c) ounsinngecthteedlanpgiupaignegC#c,othmepdoevneelonptms einst, ttohoel MeSarVliiseuraltShteudtieos, tainndgthperdoactaebsassecasynstbeme Ocoramclpe lDeBte. d, t4herEthenebtepyriipnmegooirnrdmimeor:vizIenmintehgnist psotfruaodncy,ea“lsresenatdderyei-nlmagya”nsmu. efaIafcntsuthereietdheperinpptereofrcroiunmregmthoeenrwtdfaerroremhiosaussdueebt-otceotrhnmetrsaiincteteotdromawwanaiutihtfaionctusuttarellcraowtinohnso.imdeanriunfagctuthrees installation readiness status, piping components that cannot be installed are entered,
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