Effektiv Produksjon av Avansert Skipsutstyr

Efficient production of advanced ship equipment (EFFEKT) In EFFEKT, the companies Brunvoll and Oshaug Metall have collaborated with the R&D institutions SINTEF, NTNU and Møreforskning Molde to achieve more efficient production of complex products that are adapted to unique customer needs (engineering-to-order, ETO). The overall objective is to develop production strategies and technologies for competitive production of high-tech ship equipment in Norway. The project has addressed production challenges including processes, information flow and methods in a plant and in the supply chain, and have been based on the following objectives; 1. Develop strategic concept for efficient production of ETO ship equipment 2. Develop methodology for next generation lean manufacturing logistics for ETO products 3. Develop technology and method for automated production of customized products in small quantities that require frequent adjustments 4. Develop decision support for real-time and event driven production management 5. Implement the research results in the form of demonstrators for world class automated ship equipment manufacturing A method for decisions of automation is developed that contribute to better decision-making when evaluating new automation projects. The APROS method (Automation Project Selection) is based on the strategic priorities of a manufacturer and supports systematic assessment of potential process and technology candidates for automation in ETO manufacturing. It was developed and tested in several cases at Brunvoll, and includes analysis and ranking of automation capabilities in a factory in several steps. By using the method, ETO companies can improve their chances of achieving better results of automation. A method for lean ETO manufacturing is developed together with planning models to establish continuous flow and shorter lead times. Traditional lean methods and models, such as value stream mapping (VSM), is used as a starting point and adapted ETO setting. The method has been tested at Brunvoll to define a new planning and control strategy based on lean principles and models to provide better support when planning the production of thrusters. Planning models have been developed that provide better support for capacity assessment of bottleneck resources, both in terms of overall product mix, sequence of products and takt. The models contribute to better control of product flow and more balanced utilization of resources. A method for robotic welding of ETO products for more efficient offline programming is developed based on advanced robot vision (3D camera) and force control and is implemented by Brunvoll. Furthermore, a concept for robotic shaping of cast moulds is developed based on Oshaug Metall's products for more efficient modelling of cast components which will replace the need of traditional model production of moulds. A collaborative supply chain concept based on information sharing is designed to reduce lead times for components delivered by suppliers to ETO manufacturers. It contributes to improved flow and shorter lead times through enhanced exchange of information related to demand forecasts and production plans as well as traditional orders. Suppliers get access to better information to use in their own production planning, which in turn leads to more efficient deliveries of components. The concept was developed and tested in the supply chain of Oshaug Metall and Brunvoll. The project has developed demonstrators in terms of models for supporting main planning and takt-based weekly planning, a collaborative supply chain concept and measuring systems, and lab demos for robotic welding with 3D vision and force control, and automated shaping of moulds. Several of the demonstrators are developed further into practical solutions that are also tested and deployed in the companies. The results are expected to have significant contribution in the companies to achieve a more efficient production and supply chain, especially with regard to quicker delivery to customers. Measurements indicate that it is possible to halve the lead time for ETO manufacturing by introducing lean practices with ETO adaptations in planning and control. Brunvoll has measured significant time savings and the throughput time from the start of production to final thruster is halved from 8 to 4 weeks. This has in turn contributed significantly reduced handling of parts, reduced inventories of direct-flow parts, less work-in-progress and a better overview of delayed parts. In the supply chain Oshaug Metall has by better use of plans and forecasts from Brunvoll, achieved lower inventory of finished goods, fewer changes of orders and increased forecast quality. Brunvoll has also achieved a significant reduction in both delivery times and inventories of parts supplied from Oshaug Metall.

Norske skipsutstyrsprodusenter leverer typisk kapitalintensive, avanserte, og kundetilpassede produkter i små volum til maritime kunder i olje og gassindustrien. Denne produksjonsformen heter engineer-to-order (ETO) og er svært krevende og arbeidsintensiv . Effektivisering av ETO produksjon har hittil fått lite oppmerksomhet hverken i forskning eller praksis, og den preges derfor av høye kostnader og lange ledetider. Dette fører til at stadig flere forretningsmuligheter mistes til konkurrenter i lavkostlan d. Prosjektets overordnede ide er at avansert teknologi for automatisering, datafangst og planlegging nå muliggjør et effektivitetsskifte innen produksjon av ETO produkter. Hovedmålet for forskningsaktivitetene i EFFEKT er derfor å utvikle produksjonsst rategi og teknologi for konkurransedyktig produksjon av høyteknologisk skipsutstyr i Norge. Dette hovedmålet skal realiseres gjennom følgende delmål: (1) Utvikle et strategisk konsept for effektiv produksjon av ETO skipsutstyr. (2) Utvikle metodikk for n este generasjons lean produksjonslogistikk for ETO produkter. (3) Utvikle teknologi og metode for robotisert produksjon av kundespesifikke produkter i små antall. (4) Utvikle beslutningsstøtte for sanntids- og hendelsesdreven produksjonsstyring. (5) Imple mentere forskningsresultatene i prosjektet i form av demonstratorer for automatisert skipsutstyrsproduksjon i verdensklasse. For å løse utfordringene som er adressert i EFFEKT, er det behov for å kombinere ekspertise fra produksjonslogsistikk, automatise ring, og IKT. Et flerfaglig konsortium har derfor blitt sammen av Norges beste forskningsmiljø innenfor disse fagfeltene. Forventet verdiskapningspotensial for industripartnerne er blant annet en halvering av alle ledetider, en 25-50% reduksjon i produksj onskostnader og en halvering av alle lagerbeholdninger. Prosjektets resultater vil være relevante for å styrke hele den norske maritime utstyrsindustrien og leverandørindustrien til olje og gass.