Library for simulating complex production processes in shipbuilding

Classification and brief description

The STS Simulation Toolkit (Simulation Toolkit Shipbuilding) is a specialised library for simulating production and logistics processes in shipbuilding. It was developed jointly by Flensburger Schiffbau Gesellschaft and SimPlan and is based on the simulation software Plant Simulation.

Shipbuilding places particular demands on simulation models. Products are mostly one-off items with a high degree of variation. At the same time, different manufacturing principles are combined and large components must be transported and stored over long distances.

The STS Module Box was developed to enable these complex processes to be modelled and analysed efficiently. The model also takes into account dependencies between processes as well as unplanned disruptions.

Typical areas of application

The STS building block system is used for the analysis and planning of production and logistics processes in shipbuilding.

Typical applications include:

• Planning and optimisation of shipyard processes
• Analysis of manufacturing processes in steel construction and outfitting
• Investigation of material flows and transport processes for large sections
• Assessment of capacities and bottlenecks in production
• Simulation of storage and transport processes within the shipyard

Furthermore, the approach can also be used in related fields, for example:

• Port logistics and cargo handling processes
• Planning of offshore wind farms
• Simulation of construction site and building processes

Functional scope and structure

The STS module library comprises a wide range of modules for modelling typical processes in shipbuilding.

These include, amongst others:

• Steel fabrication processes
• Outfitting and assembly processes
• Transport and logistics processes within the shipyard
• Storage and movement of large components or sections
• Loading and unloading of ships and vehicles

The modules can be integrated directly into a simulation model and adapted to project-specific requirements via parameters. This allows complex production systems to be modelled in a structured and efficient manner.

Special features and scope

A key feature of the STS module library is its focus on one-off production. In shipbuilding, products often differ significantly from one another, making production processes variable and difficult to standardise.

The module library therefore takes into account typical conditions of such production systems, for example:

• complex dependencies between processes
• varying production sequences
• unplanned events and disruptions

This modelling logic allows even complex shipyard processes to be realistically represented.

Integration and data connectivity

The STS module-based system is based on Plant Simulation and can be integrated into existing simulation models. Input and planning data can be imported into the model via appropriate interfaces.

Typical data sources may include, for example:

• Planning data from production systems
• Layout and process data from planning tools
• Project-specific logistics and process data

Target audience and benefits

The STS module library is primarily aimed at companies and organisations wishing to analyse and optimise complex production or logistics processes in shipbuilding.

Typical users include:

• Shipyards and shipbuilding companies
• Planning and engineering departments
• Simulation experts
• Research and development projects

Using the library offers several advantages:

• significant time savings when modelling complex processes
• easy integration and parameterisation of the modules
• structured development of simulation models
• high stability and reusability of the modules

Availability

The STS module library was developed jointly by Flensburger Schiffbau Gesellschaft and SimPlan and is continuously being further developed.

A Shipyard Simulation Demonstrator is available for demonstration purposes and can be provided on request.

Simulation in one-of-a-kind production

This English-language video explains the opportunities, benefits and challenges of ‘one-of-a-kind’ simulations. It demonstrates how the STS modular toolkit maps complex processes, shortens development times and increases planning reliability, even beyond shipbuilding.

Sneak preview of the Shipyard Simulation Demonstrator