Abstract
The dock shop hoisting process is the bottleneck stage of the entire shipbuilding lifecycle, with a crucial influence on a shipyard's competitive goals of cost and delivery time. The complexity and particularity of the hoisting process, which tends to be a project-type manufacturing process, leads to more difficulties in exploiting potentialities for a productivity improvement via computer simulation technology. In order to overcome the deficiency of the previous modelling and simulation methods in terms of the applicability to project-type manufacturing cases, the characteristics of the hoisting process are carefully investigated, followed by a discussion of the specific requirements of constructing a simulation suitable for this kind of process. Then, we apply a task-centric idea to establish an information flow and work flow integrated model (named IWI) that can properly abstract the dynamic behavior of the hoisting process, in which the interrelations between the production elements are quite different from those in the general discrete manufacturing process. According to the mechanism revealed by the IWI model, a simulation algorithm is further designed as the foundation to realize a subsequently developed prototype system. The validity of the proposed modelling and simulation method is tested with a case study on a group of actual dock shop hoisting processes, with multiple indices indicating how well the production system performs output through the simulation experiment.
Highlights
The manufacturing processes in a shipyard take various forms due to the characteristics of ship products
If we review the IWI model, it is easy to determine that each ACD is just coincident with the process concept of the process interactive method because the activity cycle diagram abstracts the very lifecycle behavior of the entity
This study presented a systematic analysis of individual requirements that drive the development of a modelling and simulation method specialized for project-type manufacturing processes, such as the dock shop hoisting process
Summary
The manufacturing processes in a shipyard take various forms due to the characteristics of ship products. As the heuristic algorithm, genetic algorithm, swarm intelligence algorithm, etc., in reality the production system can scarcely achieve such a high performance due to the simplified assumption of the scheduling model and uncertain disturbances concealed in the factory [1] This phenomenon is especially quite obvious to the dock shop hoisting process. Due to the inability to effectively predict the shop-floor behavior at the planning stage, trial and error and modification of incorrect planning information after occurrence of on-site incidents have become very prevalent in dock shops, resulting in a severe obstacle to improving the shipyard’s competitiveness from perspectives of cost and delivery time To deal with this challenge, computer simulations provide a powerful solution to accurately investigate production capacities and improve the accuracy of the production plans through mapping and operating the actual production system in the virtual world, thereby shifting the decision making from a past paradigm based on mere intuition or experience to a modern paradigm based on concrete quantitative data. Computer simulation seems to be the only way to optimize the manufacturing performance without any increase in the physical investment
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