[논문]조선에서 대량 맞춤화의 영향

권치명; 임상규; 스톨치

doi:10.9709/jkss.2012.21.1.069

조선에서 대량 맞춤화의 영향
Impact of Employing Mass Customization in Shipbuilding 원문보기

한국시뮬레이션학회논문지 = Journal of the Korea Society for Simulation, v.21 no.1, 2012년, pp.69 - 79

권치명 (Dept. of MIS, Dong-A University) , 임상규 (Dept. of ISE, Gyeongsang National University) , 스톨치 (Dept. of ISE, University of Washington)

초록
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대량 맞춤화 생산에서 목표 중 하나는 생산 비용이나 제품 인도 스케줄을 크게 변화시키지 않고 특정 고객의 요구를 만족시키는 생산을 달성하는 것이다. 조선 항공과 같은 대형 조립-생산 산업에서의 맞춤화는 이에 따른 부품이나 또는 부품의 중간조립품인 모듈의 변화를 가져오게 된다. 본 연구는 조선 분야에서의 사례 연구를 통하여 고객의 맞춤화에 따른 생산 스케줄의 변화가 선박 인도에 미치는 영향을 분석하고자 한다. 대단위 조립 생산에서 대량 맞춤화는 맞춤화의 요구 수준에 따라 엔지니어링 및 조립-생산 시간이 변화한다. 본 연구는 조선 산업에서 처음으로 대량 맞춤화를 수행하는 생산 방안을 제안하고 이론적조선 생산 과정을 간략히 기술한 시뮬레이션 모형을 통하여 다양한 수준에서의 대량 맞춤화가 선박 인도 일정에 어떠한 영향을 미치는가를 평가하였다.

Abstract ▼ AI-Helper

One of the goals of mass customization is to permit changes in the product to meet specific customer requirements without substantially impacting the cost or delivery schedule. In large assembly manufacturing industries, such as shipbuilding and commercial airplane production, customization takes place by changing components and/or modules, sometimes called interim products. Using shipbuilding as a case study, it is possible to study the impact of such changes using mass customization principles on the schedule. In large assembly manufacturing, mass customization changes would cause changes in engineering time and production time, based on the amount of change required by the customization. This work first proposes a structure for implementing mass customization in shipbuilding and then uses simulation of a simplified, theoretical shipbuilding process to evaluate the impacts of various levels of change on delivery performance.

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문제 정의

, New Orleans, Louisiana, in 1985 (Bunch 1995). Although this study represents a somewhat outdated production process, it provides a solid foundation for analysis of potential changes resulting from customization decisions. It is still one of the most comprehensive published shipbuilding production planning studies and is thus chosen as the basis for this simulation study
The major objective of this simulation experiment is to investigate the impact of customization changes on the shipbuilding completion schedule. A certain level of customization at engineering and assembly may cause production delay so that the final ship delivery may not meet the original delivery schedule.
This approach is made effective by the support of the functional volume approach with parametric design rules. This paper has described how mass customization can be implemented in shipbuilding. To date, no studies have specifically presented this concept.

제안 방법

The shipbuilding process simulation model could be adjusted to a more suitable (though much more detailed and complicated) one in order to better reflect specific shipyard characteristics. Based on the process, the impacts of timing and amount of customization on production performance and delivery would be evaluated using actual shipbuilding data, which would enable the shipbuilder to be well prepared for effective planning and scheduling and even for a quick and proper response to specific owner requirements presented at the contract design stage.
In this study, a simulation model of a simplified and theoretical shipbuilding process based on a notional shipbuilding project of the ship PD-214 is developed to evaluate the impacts of various levels of customization in engineering and assembly on delivery schedule. In conducting simulation, stochastic production times were assumed and the effect of learning curve improvements was considered.
Starting with a parent design, design rules and tools can be developed to permit rapid completion of a contract design and an associated cost estimate that can be used for bidding. The approach is based on developing functional volumes, such as cargo volume, engine room, deck house and bow, and then using parametric rules to resize these volumes to respond to customer requirements. The tools permit the use of first principles to validate the design and then seamlessly pass the design data to a cost estimating module.
The design and engineering approach uses a combination of existing interim product designs, including production processes associated with these interim products. Taken at its simplest form, this design approach is illustrated by the following Fig.
Once designers have access to these data, in terms of a specific ship design project, based on the owner’s technical mission requirements, specification and government and class rules, the designers can select an excellent parent ship from the database for reference. The design process begins with a major zone family album, from the database, made up of choices for the four major zones of bow, cargo, machinery space and accommodations. The following Fig.
This experiment will use a high level or master milestone schedule for design and production, and then assume duration changes for design and production of interim products. In shipbuilding production processes, the customization and its potential impact on delivery schedule mainly occurs at engineering and the assembly production stages.

대상 데이터

A set of simulation experiments is conducted at the previously defined levels of customization in engineering and assembly. At specific customization levels in engineering and assembly, the simulation experiment consists of 10 independent replications. Each replication stops when 250 ships are built in the shipyard.

성능/효과

In this experiment, it is assumed that the curve rate is 95% and there is no more improvement in production time when the accumulated production unit reaches 100. Avondale’s shipbuilding data (from the PD-214 study) are used to estimate the value of a in equation (1).
In conducting simulation, stochastic production times were assumed and the effect of learning curve improvements was considered. The results of the simulation experiment show how on-time delivery percentage is decreasing as customization change increases. It also showed that as a result of the continued learning curve improvements, the degradation of on-time delivery performance was less than 15% (for large customization in engineering and production).
The simulation result for the construction period shows it is about 10 weeks longer than Avondale's deterministic schedule of 140 weeks.

참고문헌 (11)

Bunch, H., "Construction Planning and Manpower Schedules for the Single-Screw, Multi-Purpose Mobilization Ship, PD214 in Cooperation with Avondale Shipyard, Inc., New Orleans, Louisiana", Technical Report, Department of Naval Architecture and Marine Engineering, University of Michigan, Ann Arbor. 1995.
Burnett, G., Finke, D., Medeiros, D. and Traband, M., "Automating the Development of Shipyard Manufacturing Models", Proceedings of the 2008 Winter Simulation Conference, pp. 1761-1767, 2008.
He, D. W. and A. Kusiak, "Design an Assembly Line for Modular Products", Computers and Industrial Engineering, Vol. 34, No. 1, pp. 37-52, 1998.

상세보기
Hyde, W.F., Improving Productivity by Classification and Coding and Data Base Standardization, Marcel Dekker, Inc., New York, 1981.
Lu, R. F., Asynchronous Stochastic Learning Curve Effects in a Large Scale Production System, Ph.D. Dissertation, Department of Industrial Engineering, University of Washington, 2008.
NSRP, Design for Production Manual, 1998.
NSRP, Project 99-21 Develop and Implement World Class U.S. Material Standards and Parametric Design Rules to Support Commercial and Naval Auxiliary Ship Construction, 2003.
Pritsker, A. and O'Reilly, J, Simulation with Visual SLAM and AweSim, John Wiley and Sons, New York, 2008.
Softley, J. and Schiller, T., "An Approach to Advanced Ship Design Using Parametric Design Templates", SNAME Transactions, Vol. 110, p. 255, 2002.
Storch, R. L., Lim, S. and Kwon, C., "Impact of Customization on Delivery Schedule", Journal of Ship Production and Design, Vol. 27, No. 4, pp. 186-193, 2011.
Wright, T. P., "Factors Affecting the Cost of Airplanes", Journal of Aeronautical Science, February: pp. 124-125, 1936.

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조선에서 대량 맞춤화의 영향
Impact of Employing Mass Customization in Shipbuilding 원문보기

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