Intelligent initial model and case design analysis of smart factory for shipyard in China

Abstract

At present, due to the lack of core technology and technological innovation ability, the design technology of traditional shipyards in China is backward. The operation mode of front-line workers in shipyards is highly dangerous. There are problems that endanger the physical and mental health of workers, such as noise and paint mist pollution, which lead to low production efficiency of workers and difficulties in personnel allocation. Under this background, “shipyard labor shortage” and other similar situations followed. If the concept of smart factory is introduced into traditional shipyards, the above problems can be effectively alleviated and solved. However, due to the complexity of ship product structure processing and manufacturing, the definition of smart shipyard in China is still vague, and the research process of smart shipyard is relatively slow. Aiming at the vague functional concept of smart shipyard, the lack of research on information design and management, smart production process and smart implementation process, this paper provides a conceptual architecture design model of civil smart shipbuilding factory. The functional definition of smart shipyard is discussed, and the initial conceptual model of smart shipyard is established, including information network platform model, smart production process model and smart implementation process model. The application case verifies the above model. Firstly, the information network platform model of α group is constructed, and the group brain control system is established. Secondly, the smart production process of shipyard A under α group is established. Finally, the smart implementation process of shipyard A is designed. The case study shows that: All ships completed 100% modeling, and the pre-outfitting rate increased to about 95%. By using the wire cutting robot, the production efficiency is increased by 70%. In the smart factory mode, the 60,000 tons bulk carrier can save 35thousand dollars labor costs and 11 million dollars in shipping fuel costs each year. The shell steel plate of the 300,000 tons ore carrier is reduced by 212 tons, and the weight is reduced by 10.5%. Case shipyard A under α group using the above smart factory model can save about 0.7 million dollars labor costs per year; reduce fuel costs by about 2.2 million dollars per year; saving 2.5 million steel usage per year. In total, shipyard A reduced expenditure by about 5.4 million dollars in one year.