Shipyard Proves Order Fulfillment Capability and Gains Visibility into Production Facility and Distribution

Problem:

Shipyard Production Simulation

Admiralty Shipyards JSC, is one of the oldest and largest shipyards in the Baltic region, serving government and commercial customers world-wide for more than 300 years. The shipyard's military orders are primarily submarines, but also include non-military repair and the modernization and construction of other underwater technical innovations for oceanic development.

Faced with a large order for diesel powered submarines, Admiralty Shipyards JSC must evaluate whether the current production facilities can fulfill the order, and if not, what amount can be produced by the year 2016. Admiralty Shipyards JSC is also seeking confirmation that an additional production facility will not be needed to complete the order.

Shipyard Manufacturing Optimization

Solution:

The Shipbuilding & Ship Repair Technology Center JSC was employed to analyze and resolve the production issue, who chose AnyLogic simulation and modeling as the decision making tool due to its multimethod modeling capabilities. To begin, JSC modeled the production processes of the manufacturing facility as a whole and the distribution of the vessels being built. To increase model accuracy, JSC also simulated the connections between multiple production departments, characteristics of the orders, and characteristics of all assembly parts (i.e. quantity, weight, labor effort required, construction start dates, etc.).

JSC ran experiments or simulations with varying parameters which included process deviation throughout production departments and allocation of assembly parts among production departments at the beginning of each quarter. The results manufactured by the simulations included production plan fulfillment statistics, equipment workload percentage, production department workload percentage and assembly parts’ allocation amongst production departments in each quarter. Furthermore, the equipment workload percentage and production department percentage had a stipulation of 80% or less in order to remain consistent with JSC statistics.

Results:

Production Planning at a Shipyard

AnyLogic simulation and modeling proved the production plans of Admiralty Shipyards JSC could be fulfilled in the current manufacturing facilities and a workload percentage of 80% or less.

This enabled JSC to obtain the large order, and without the cost of building additional facilities. The model also gave JSC increased visibility into their production, distribution and connections between departments.

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