Simulation

Handling of Cargo

With the aim to minimize the time a ship spends in port, the simulation of loading and unloading has been an integral part of design here at FSG for many years. Through the use of simulations we have the ability to illustrate ramps, decks and the direct environment surrounding the ship in such a way that loading and unloading times may be determined for any type of loading situation.

In the scope of an offer, the design of a RoRo ship includes a description of one or more loading situations that states how such a loading scenario might look for the ship. In order to improve the design, simulation experiments are conducted for any potentially arising design variations, with the results for loading times included. The most diverse vessel parameters, such as speed, turning radius or carrying capacity and parameters for the surrounding areas, such as port side bottle-necks, are given careful consideration in the model and may be modified very quickly, if necessary.

A logistics capacity assessment report is rendered parallel to the ship’s design process, so that it is still possible to influence the design process. In order to be able to maximize the modeling speed, a modular concept was selected to begin with. The STS module (Simulation Toolkit Shipbuilding) which has been developed for manufacturing was expanded upon to add building blocks and functionalities for onboard logistics. An add-on was developed under the name of STS-ShipLog with which various low-cost loading situations can be modeled. This expansion of modules works in harmony with Basis-STS, so that already existing modules, such as transport control or personnel control can, for example, be applied to the ship’s logistics models, as well.

The parameters for the model, supported by user-friendly dialogues, can be modified without any difficulty. Control variables, for example, are the number of transport vessels, various ramp configurations, varying loading strategies, as well as ramp gradients. An unfavorably designed ramp can bring about that the drivers may drive only very slowly up and down the ramp to avoid damage to the vehicles. An improvement to the cross-section of the ramp will permit faster passage across the ramp.

With the aid of simulation it can be illustrated how great the influence of such measures really is. If, for example, a ramp does not represent a bottleneck during loading operations, an improvement to the ramp speed is not necessary if this would raise the cost of new construction, or if the number of storage/deposit spaces onboard is decreased.

The use of simulation technology will improve a ships’ performance during numerous loading and unloading situations considerably. This ultimately leads to clearly reduced port times and an improved ability to keep to the ship’s time table, or even a drastic reduction in the engine performance required, which in turn will result in clearly reduced fuel consumption, if the time in port could be minimized to a point where the ship’s speed might be reduced in transit.

Evacuation Scenario

Safety first!

FSG places supreme value on the motto Safety First! Not only the knowledge of currently valid regulations and their correct interpretation and usage, but also the consistent parallel activity of the continuing research and development in the field of ship safety are an integral part of a shipyard’s identity.

The subject of safety for crew, passengers, ship and cargo encompasses a wide range of application. For example, questions related to escape routes, means of rescue and structural fire protection have a great influence on early design. Owing to the comprehensive approach by FSG, safety is considered to be more of a diversified issue. Excellent behavior in the sea state in combination with proof of adequate stability in the sea state at all times, safe maneuvering and navigation, providing required redundancy, including questions regarding the ship’s effective care and maintenance, as well as issues regarding environmental protection, are all such examples involving the philosophy to make safety paramount in design and construction.

While implementing appropriate measures in daily assignments, specifically developed tools and commercial programs by FSG, such as AENEAS in the area of evacuation simulation are being used. Risk analysis is one helpful tool to recognize potential weak spots in the selected technical concept at an early point. The shipyard is constantly involved in this collaboration with corresponding research and development programs. As an example, this includes the following titles: SAFEDOR, SAFECRAFTS, FIRERESIST and FIREPROOF.

This is how we succeed in providing a high level of safety for our products, in safeguarding our customers’ investment, and satisfying the concerns involving the protection of man and the environment.

Offshore Windpark Logistics

Simulation technology can also be used as a basis for determining the design and operation of logistics processes for the installation of windparks. The interdependence factors in the logistics chain may be evaluated in terms of their dynamics and under consideration of various influences. In this way, various installation concepts for windparks may be compared across a large number of adjustable fringe conditions, in order to determine the most suitable choice. This includes, for example, types of jack-up barges and the type of cargo, supply, and variations thereof.

FSG and its collaborative partners have already performed studies in simulation of the installation of offshore windparks. In doing so, based upon the STS special simulation modules and modules for efficient model construction and -operation have been developed. Depending upon the goal and availability of simulation parameters, the processes can be depicted in varying degrees of detail. The modular construction of the components facilitates a depiction of any given type of work procedure and level of influence. The adjustment options of the simulation models include:

• number and properties of the ship (cargo capacity, speeds depending upon shipping routes, etc.)
• the design of the windparks (number and types of wind energy systems, distance between the structures, etc.)
• the distance between windparks and ports, and
• processing times and speeds (jacking speed, preparation, assembly time per type and fringe conditions, etc.)

The variability of adjustment options in the simulation models is expandable in any direction, as a result of using STS modular systems.

Besides a large number of technical and/or organizational influences and conditions, weather conditions, too, may be considered in the simulation process. FSG has weather information available for various marine territories, including actual and statistical data. With the aid of the weather AP module from STS the changing weather parameters are assessed in terms of weather conditions. These weather conditions, or a prognosis in the sense of a weather forecast, may then be defined in terms of workflow, such as transport by crane, or jack-up procedures.

Moreover, times and speeds may be adjusted on the basis of weather parameters which may be changing over the course of the simulation process. In this way, weather influences can be modeled for the use in logistics and in assembly processes, all the way down to labor/time loss assessment due to bad weather conditions.

Port Logistics - Concept

The ship/port interface and port logistics often have a tremendous influence on a ship’s transit time. In order to gain a precise evaluation of this time, port logistics are included in the simulation analysis, on a case to case basis. Such simulation has already been used repeatedly and very successfully to evaluate concepts with regard to RoRo- or ferry terminals.

RoRo vessels are, unlike any other type of ship, designed for efficient means of transshipment. As a rule, only few services make port calls at terminals, and the number of ships used in the process is manageable. Consequently, the task of organizing the terminal may be adapted to the ships’different needs. The infrastructure of RoRo terminals is set up in a flexible way, so that a quick adaptation to changing ship units can be realized. A critical element remains in the interface between terminal and ship. With the simulation of RoRo terminals, the coordination of loading and unloading situations of the ships in the port’s infrastructure can also be illustrated. Any questions with regard to the required capacities of means of transport or port times may now be answered in the complete system including ships and port.

The modeling of RoRo terminals is carried out with the aid of the STS simulation module. In order to take into account the additional requirements of this specific application, the following simulation functionalities were complemented in an add-on library:

• Terminal Control
• Gate
• Bay (for trailors)
• Pier
• Parking lanes for accompanying vehicles
• Berth

Functions for 3D animation were implemented for use in the simulation modules which are employed to model RoRo terminals. In addition, we were able to draw on already existing modules designed for the organization of transports, such as transport control, lanes, etc.

Optimized Production

Beginning in 1997 Flensburger Schiffbau-Gesellschaft implemented simulation technology very successfully as a tool to plan the future development of production. To do so, the simulation model for production is configured according to the new layout which is being developed. A ship which is typical for FSG’s product range is then selected to be a reference product and made available to the simulation model for data input in highly detailed form, all the way down to the individual parts.

Based upon production logistics and -performance of this reference ship, modifications in the layout are evaluated. The actual process of shipyard development in terms of production technology is carried out by a team of employees from planning and production, and continually integrated into the simulation process and evaluated.

With the aid of simulation, precise analysis of the process of production- logistics and performance in a modified production setting is now possible. A vital parameter in evaluating the simulation runs may be the cycle time for the reference ship. For this time factor, a target time may be defined in accordance with project goals and any further shipyard developments. The achievement of this target figure may now be checked and substantiated through the further development of the shipyard layout. On the way to achieving the targeted cycle, the use of the individual production stations to full capacity will provide information regarding any bottlenecks which may still exist. These hence discovered bottlenecks will then provide a starting point for further improvement of the layout involving the entire project team.

Thanks to the work involved in the integration of simulation technology in the process of production planning and the hence developed interface for the CAD-data, it is now possible to test new production concepts, including the involvement of other ships.

Simulation technology has been employed in planning all of the investment projects which have been completed in recent years. The beginning of this was marked by the integration of a new profile production in the year of 1997/98. The greatest projects so far have been the design of a new panel production system to double capacity, and the development of a new production system for parts and subassemblies.