• International Journal of Naval Architecture and Ocean Engineering
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• v.12 no.1
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• pp.20-37
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• 2020

In this paper, we propose a simulation method based on backward simulation and process-oriented simulation to take into account the characteristics of shipbuilding production, which is an order-based industry with a job shop production environment. The shipyard production planning process was investigated to analyze the detailed process, variables and constraints of mid-term production planning. Backward and process-centric simulation methods were applied to the mid-term production planning process and an improved planning process, which considers the shipbuilding characteristics, was proposed. Based on the problem defined by applying backward process-centric simulation, a system which can conduct Discrete Event Simulation (DES) was developed. The developed mid-term planning system can be linked with the existing shipyard Advanced Planning System (APS). Verification of the system was performed with the actual shipyard mid-term production data for the four ships corresponding to a one-year period.

• Korean Journal of Computational Design and Engineering
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• v.16 no.6
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• pp.449-457
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• 2011

The productivity improvement is indispensible to shipbuilding industry for maintaining the world's No. 1. Simulation based production recently has been an issue as prat of efforts to high efficiency production and Korean shipyards requests simulation system tools specialized in a shipbuilding industry. IT convergence project between conventional shipbuilding industry and IT simulation technology has been carried out and integrated simulation framework was proposed as a way to overcome sporadic developments. The framework would provide reusability of kernels and modules and also ensure for expansibilities to other production simulations. The fact that production simulation system should reflect shipyard requirement would be most important. We suggest an analysis process of customer requirements and functional requirements for production simulations. It is partially based on concepts of software engineering and axiomatic design. The process is applied to a design of configuration for simulation framework.

• Journal of Korean Institute of Industrial Engineers
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• v.23 no.1
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• pp.197-213
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• 1997

It is not easy to find a good production schedule which can be used in practice. Therefore, production scheduling simulation with a simple dispatching rule or a set of dispatching rules is used. However, a simple dispatching rule may not create a robust schedule, for the same rule is blindly applied to all internal production processes. The presumption is that there might be a specific combination of appropriate rules that can improve the efficiency of a total production system for a certain type of orders. In order to acquire a better set of dispatching rules, simulation is used to examine the performance of various combinations of dispatching rule sets. There are innumerable combination of rule sets. Hence it takes too much computer simulation time to find a robust set of dispatching rule for a specific production system. Therefore, we propose a concept of the knowledge based simulation to circumvent the problem. The knowledge based simulation consists of knowledge bases, an inference engine and a simulator. The knowledge base is made of rule sets that is extracted from both simulation and human intuition obtained by the simulation studies. For a certain type of orders, the proposed system provides several sets of dispatching rules that are expected to generate better results. Then the scheduler tries to find the best by simulating all proposed set of rules with the simulator. The knowledge-based simulator armed with the acquired knowledge has produced improved solutions in terms of time and scheduling performance.

• Korean Journal of Computational Design and Engineering
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• v.18 no.3
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• pp.224-233
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• 2013

For the scheduling and the job assignment of the ship hull production design which is a process-based work, we suggest the simulation-based scheduling using the discrete-event-based business process simulation. First, we analyze the ship hull production design process from the perspective of a job assignment to make it into the simulation model using DEVS (Discrete Event System Specification) which is the representative modeling method for a discrete-event simulation. Based on the APIs of the open-source discrete-event simulation engine, we implement the simulation using the Groovy script. We develop the scenario generator in which the user defines detail information of the construction drawing and its member blocks, and design engineers information, and the various setting for the simulation including the job assignment strategy. We use the XML files from this scenario generator as inputs of simulation so that we can get simulation result in forms of Gantt chart without changes of the simulation model.

• Proceedings of the Korea Society for Simulation Conference
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• 1998.10a
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• pp.65-65
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• 1998

Manufacturing systems like a motor production process are analyzed using simulations than numerical analyses and/or heuristic methods due to their stochastic properties. The SME(small and medium enterprise) producing automotive motors that develop CIM systems to improve production performance is focused as an application site. We analyze and understand the system exactly using layout based simulation, and then we will suggest the initial feashible production-plan dependent on the layout to overcome weak-points of the current system(i.e., high WIPs, bottle-neck processes, due-date delays and etc.). And, solutions are suggested to increase performances of SMEs producing automotive motors in this paper. The simulation model built in this study is moedlled and analyzed with fully object-oriented methodology using SiMPLE++TM according to properties of production processes of the automotive motor. And, we will introduce ways to verify the model with developed templates for reusability when new needs will be occurred such as designing a new ship, extension or rearrangement of the system, change of production-plans, receiving urgent orders, and so on.

• Korean Journal of Computational Design and Engineering
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• v.17 no.2
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• pp.111-122
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• 2012

Capacity planning plays an important role not only for master production plan but also for facility or layout design in shipbuilding. Product work breakdown structure, attributes of production resources, and production method or process data are associated in order to make the discrete event simulation model of shipyard layout plan. The production amount of each process and the process time is assumed to be stochastic. Based on the stochastic discrete event simulation model, the production capacity of each facility in shipyard is estimated. The stochastic model of product arrival time, process time and transferring time is introduced for each process. Also, the production capacity is estimated for the assumed master production schedule.

• International Journal of CAD/CAM
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• v.6 no.1
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• pp.3-8
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• 2006

The application of three-dimensional (3-D) CAD has been popularized for design and production and digital manufacturing has been spreading in many industrial fields. By simulation of the production process using 3-D digital models, which are the core of CIM (Computer Integrated Manufacturing) system, the efficiency and safety of production are improved at each stage of work, and optimization of manufacturing can be achieved. This paper firstly describes the concept of "simulation based production" in shipbuilding and also digital manufacturing; the 3-D CAD system is indispensable for effective simulation because ship structure is three dimensionally complex. By simulation, "computer optimized manufacturing" can be possible. The most effective fields of simulation in shipbuilding are in jobs where many parties have to cooperate, while existing two-dimensional drawings are hardly observed the whole structures due to interference between structures or equipment of complex shape. In this paper some examples of the successful application in IHIMU (IHI Marine United Inc.) are shown: assembly of a pipe unit, erection of a complex hull block, carriage of equipment, installation of a propeller, and access in an engine room.

• Journal of the Korea Society for Simulation
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• v.8 no.2
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• pp.87-100
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• 1999

A manufacturing environment without a computerized system causes numerous problems, since many important decisions are made based on the experience of veteran staffs. Especially, when a strategy for the improvement of manufacturing efficiency is considered, it is hard to predict the effect of the strategy. A solution to the problem without large investment of the computerized system is the simulation study. This paper shows the modeling and simulation based on DEVS(Discrete Event System Specification). Two types of models are implemented, one for representing the current production strategy and the other for the new strategy. The new strategy is expressed as priority rules within the model. The process in concern is the metal grating production process in which the size of the group, for applying a specific cutting and scheduling strategies, is one of the important factors in improving the production efficiency. Some reliable criteria for the evaluation related to the production effeciency are established from the simulation study.

• Proceedings of the Korea Society for Simulation Conference
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• 1998.03a
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• pp.106-110
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• 1998

Some successful scheduling systems are based on simulation technique. However, they are relatively expensive. A cost-effective solution is to apply general-purpose simulation software to the scheduling system. This paper is concerned with developing a simulation model for MPS(Master Production Schedule) evaluation system. The target system of the model is PC production system. AIM (Analyzer for Improving Manufacturing system), a well-known manufacturing oriented simulation software, is used for modeling tool. Eventually, the model can be included into an MPS evaluation system as simulation module and a scheduler can use the system to verify the MPS in advance.

• Journal of Korean Society of Industrial and Systems Engineering
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• v.42 no.1
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• pp.64-73
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• 2019

The manufacturing companies under Make-To-Order (MTO) production environment face highly variable requirements of the customers. It makes them difficult to establish preemptive production strategy through inventory management and demand forecasting. Therefore, the ability to establish an optimal production schedule that incorporates the various requirements of the customers is emphasized as the key success factor. In this study, we suggest a process of designing the simulation model for establishing production schedule and apply this model to the case of a flat glass processing company. The flat glass manufacturing industry is under MTO production environment. Academic research of flat glass industry is focused on minimizing the waste in the cutting process. In addition, in the practical view, the flat glass manufacturing companies tend to establish the production schedule based on the intuition of production manager and it results in failure of meeting the due date. Based on these findings, the case study aims to present the process of drawing up a production schedule through simulation modeling. The actual data of Korean flat glass processing company were used to make a monthly production schedule. To do this, five scenarios based on dispatching rules are considered and each scenario is evaluated by three key performance indicators for delivery compliance. We used B2MML (Business To Manufacturing Markup Language) schema for integrating manufacturing systems and simulations are carried out by using SIMIO simulation software. The results provide the basis for determining a suitable production schedule from the production manager's perspective.