Advanced Production Systems in Japanese Shipyards

Nobuyuki Okui, Ph.D GCRMTC University of New Orleans

Contents
1. Background: Problems and issues which Japanese shipyards have faced. 2. A few examples of production systems in Japanese shipyards. 3. Application technologies of robot welding systems. (CAD/CAM Systems, Cell Control of multi-robots, Computer Integrated Manufacturing) 4. High speed welding technology. 5. Application of automation for additional work. 6. Conclusions and present / future issues.

Transition of production and number of employees

Transition of productivity and mechanized welding ratio.

Background: Problems
1. Sharp drop in demand of new shipbuilding after the oil shock of 1973. 2. Decrease in number of employees. (Early retirement plan, shift employees to the other departments.) 3. Young generation tends to avoid manufacturing. (Dirty, Dangerous, Distressing) 4. Highly educated workers expect high salaries. 5. Current workers are getting advanced in age. 6. Intensified cost competition globally.

Background: Issues to survive

1.Decreasing costs 2.Improving and stabilizing quality. 3.High productivity and high efficiency. 4.Moving away from high level skill and experience. 5.Transforming a labor intensive industry to an intellectual industry.

Background: Current trends

1. Resurgence of new shipbuilding demand. 2. Increase of work volume in double hull tanker. 3. Automation in production systems expands rapidly. 4. Growing improvement of computer technology. 5. Studying ultra-modernized production system developed by The Shipbuilders Association of Japan (82~86)

2. A few examples of production systems in Japanese shipyards

2. 1 IHI Kure shipyard 2. 2 SHI Yokosuka shipyard

Process flow of unit-panel and slit process (IHI)

Longitudinal setting equipment (IHI)

Unit-panel assembly equipment (IHI)

Unit-panel straightening equipment (IHI)

High speed FCB ( Flux Copper Backing) one-side welding equipment (IHI)

Trans. web inserting equipment (IHI)

Welding robots (IHI)

Welding robot configuration (IHI)

Welding joint for robots (IHI)

Comparison of assembly processes for flat hull block

Assembly method of double hulls block in Yokosuka Shipyard (SHI)

Layout of single panel line (SHI)

Layout of complex panel line (SHI)

Numerical-controlled welding robot for sub-assembly (SHI)

Longitudinal welding equipment (SHI)

Self-moving reformer (SHI)

Fillet welding robot for slot (SHI)

Fillet welding robot of skin plate with longitudinals, trans. Web (SHI)

Summary
2. A few examples of production systems
1.Optimize production ratio.
* Standardize the design.

*Simplify the design. *Simplify the production process. *Automated production of small steps. *Result is accuracy and quality. 2. To automate production system. *Chose the equipment to match the process. *High speed welding is required.

3. Application technologies of robot welding systems

1. CAD 2. CAM System (Off Line Programming) Cell Control of Multi-Robots Simulation Sensors 3. Computer Integrated Manufacturing

CAD
3D CAD System based on product model
Each shipyard has developed their own CAD system aimed not only for drafting but also out-putting information for manufacturing. Linked with welding robot: Welding data Welding process Material Welding position Welding edge configuration

CAM System
CAM System (Off Line Programming)
Robot motion data generation system. Data conversion system. Robot simulation system. Data transferring system.

General

view of the welding robot equipment (KHI)

General view of multi-robot system (NKK)

Welding robot of sub-assembly (Hitachi Zosen)

A typical work piece (KHI)

This is also typical work of NKK.

Typical CAD/CAM System (NKK)

Work piece arrangement display of the task assignment (KHI)

Task assignment method for each robot (KHI)

Graphical display for the robot simulator (KHI)

Method of sensing a bead connecting point (KHI)

Macro structure of multi-layer welding beads (KHI)

Appearance of welding bead at a corner of inclined-joint (KHI)

General view of panel sub-assembly line (NKK)

Schematic diagram of multi-robot welding system (NKK)

Configuration of welding robot (NKK)

Example of panel nesting (NKK)

Example of robot simulation (NKK)

Line management system (NKK)

Corner sensing by high frequency rotating arc process (NKK)

Cornering bead appearance with arc sensor joint end detection (NKK)

Bead appearance with high speed rotating arc sensor (NKK)

Appearance of bead connection section with bead end detection (NKK)

A concept of CIM

Summary of 3. Application technologies of robot welding systems

OLP is indispensable to practical application of robots and it has progressed widely. Automation of OLP is very desirable Cell Control in multi-robots welding system is applied successfully for equalization of job assignment and avoiding interference. Management information system is important for optimizing the productivity.

4. High speed welding technologies

1. Rotating arc (NKK, KHI) 2. Tandem arc (IHI, Hitachi Zosen, etc.)

High speed welding by high frequency rotating-arc (NKK)

Macro structure of rotating arc welding (NKK)

High speed welding by tandem process (IHI)

Conditions under which an undercutting occurs. X s< X m

5. Application of automation for additional work

Automated Fitting equipment Automation of plate bending process Automated one-side welding of curved block Painting robot in double hull structure

Mechanized ratio of various work in current Japanese shipyard

Fitting equipment (SHI)

Automation of plate bending process by line heating(IHI)

Welding robot for curved block one-side welding (Hitachi Zosen)

Painting robot in double hull (Hitachi Zosen)

6. Conclusions and present / future issues Summary

Automation of component production is a useful concept in one-of-a-kind industry. Automation of OLP is very desirable. The cell control technology has progressed and it supports the high productivity in robot welding system. Automated production system has contributed to decreasing cost and minimizing the number of employees.

6. Conclusions and present / future issues Present / Future Issues

Automation or mechanized processes should be advanced for fitting and painting jobs. Product managing systems which supports total business and production activities is desired in future.