3. The Application of Advanced Information Technology and Productivity Improvement
The development of Computer In tegrated Manufacturing (CIM) was begun in 1987 as a joint industry- university project, and it continues today. The purpose of the project is the transformation of shipbuilding from its traditional labor-intensive shipbuilding pattern into an advanced and modern industry. CIM aims at unitary management integration, through the computer, of the entire range of manufacturing processes from information organization point of view, such as to design, material machining, assembly and manufacture. As Fig. 1 (Shipbuilding CIM R&D Projects) illustrates, the application of CIM at actual shipyards began around 1993. At present, a development project aimed at an even more advanced level of CIM has been organized and research is underway.
Additionally, because shipbuilding is really an assembly industry, the Shipyard and Marine Parts Supplier Web Project (which incorporates the so-called CALS/EC) was launched in 1998 and is ongoing today.
3-1 Development of the Optimal Hull Form
The computational fluid dynamics (CFD) in recent years has been remarkably developed. CFD has increased the reliability and practicality of computations of fluid flow around the hull, and it has become a powerful tool used for hull form design and development. Research is underway at present aimed at the automation of hull form design by combining the most appropriate algorithms with the CFD code. CFD is transforming the old method of hull form design that depended on the experience of the designer into a new method of automated design, and it is emerging as one pillar of an integrated CFD-CAD-CIM system of shipbuilding design.
3-2 The Design Stage
Through the application of CIM the definition of what the design department does has begun to change. The new function of the design department is to input design information into a project model which embraces all pertinent information from the design to the manufacturing stages. In other words, following input from the design department, the production department inputs all production information including materials machining, subassembly, and final assembly information; then, these data are immediately fed back to the design department. The result is that designers are able to produce optimal designs by taking into consideration what is experienced in the production process.
Additionally, when the Web Project is realized, exchange of outfitting design information between equipment suppliers and parts makers on the one hand and design engineers on the other will become digitized. This will result in increased efficiency of exchange, allow for input of information on the procured equipment into the product model, and make possible overall optimization through integrated management.
3-3 Production Planning, Production Management
Through the application of CIM, the optimization of the construction procedures embodying integrated consideration of hull building and outfitting together with schedule planning can be accomplished with great rapidity. By incorporating into the system procedures, knowledge and standards, the precise instruction can be given as to the work to be done, and information to assist workers in making judgments can be provided. As a result, the problems caused by the scarcity of skilled workers can be remedied and less experienced workers can attain work proficiency and versatility in a much shorter period of time.
3-4 Mechanization, Automation
In order to make up for the scarcity of blue collar workers, mechanization and automation are essential. Improvements in these areas have already been accompanied by changes in construction methods at all shipyards. Through the application of CIM, the generation and supply of all sorts of data involved in machining and assembly have been facilitated, and mechanization and automation have been promoted. Consequently, improvement in the work environment will become possible. The move toward greater mechanization and automation requires that equipment and procedures different from those employed in the past be explored.
