MTI Journal
MTI Journal.23
Streamlining Newbuildings’ Design Through Frontloading
Takumi Nakamura
Researcher, Maritime and Logistics Technology Group*
*The job title is as of August 25, 2023
I was seconded to MTI in September 2021 from Oshima Shipbuilding Co., Ltd., and am mainly involved in research to streamline and optimize the conventional newbuilding design process. I was involved in newbuilding design work (initial design) at the shipyard from which I was seconded, but at MTI I will take on the challenge of improving processes that include these tasks, and I hope to positively contribute to these efforts.
Concerns with the Conventional Newbuilding Planning and Shipbuilding Process
As background to this research, the existing newbuilding planning and shipbuilding process contains a lot of issues, as shown in the following diagram. For example, although 3D design tools have recently been utilized in the ship design phase, the processes for classification approval and contracts/negotiations with shipping companies have not changed, and specifications and drawings in paper or PDF format are still being used. As a result, shipyards spend a lot of time preparing documents for submission based on information from 3D design tools, and shipping companies, who check ship specifications, have difficulty in reading ship specification information from paper/PDF documents, leading to a time-consuming process in determining specifications.
In addition, ship design is expected to become more advanced in terms of fuel conversion etc. in the future. Under these circumstances, we consider that there is a limit to operating with the same old processes, and that there is an urgent need to streamline and optimize the new ship planning and construction process.
Concerns with the conventional newbuilding planning and shipbuilding process
Streamlining Processes Through Frontloading Design
In order to streamline and optimize the process, this research considered the utilization of 3D models instead of existing specifications and drawings in paper or PDF format. By utilizing 3D models, we are working to develop better communication tools for contracts and negotiations among stakeholders. It is assumed that digital information, including 3D models created during design, will be utilized not only during planning and construction, but also after ships are in service. We aim to streamline processes throughout ships’ life cycles, including feedback of equipment maintenance data and operational data back to the design phase.
We consider that “frontloading design” will be realized through these efforts. The image below illustrates the concept. The vertical axis represents cost and resources, and the horizontal axis represents process progress, indicating that the further along the process, the higher the cost of design revisions become and the less easy they will become. We aim to bring forward the workload of shipyards, which currently peaks at the “detail design” and “process design” stages, to the basic design stage. However, simply bringing forward the workload to the basic design stage will increase the load on the basic design stage. Therefore, by utilizing excellent tools such as 3D models and communication tools mentioned above, we hope to reduce the workload itself by reducing the amount of simple work and rework.
Smooth decision-making through frontloading design will enable highly competitive design and procurement of ships, and in the future, we consider that it is possible to realize “joint ship design” by shipyards and shipping companies.
Image of design frontloading
Structure of Joint Research
Let me describe the structure of this research effort: Phase 1 started in March 2021 and has now been completed through Phase 3. Overall, we plan to work on Phase 5 until the end of 2024.
Currently, the project is being conducted as joint research with Smart Design Corporation (SDC), Honda Heavy Industries, Oshima Shipbuilding Co., Ltd. and NYK Line. As shown in the diagram, we are working on two major studies: one with Oshima shipbuilding and another with SDC and Honda Heavy Industries. While each of these studies is being carried out through subcommittees, a regular general meeting is held once a month to share information and hold discussions. In addition, ClassNK, NAPA Japan, and the Cooperative Association of Japan Shipbuilders are to participate in the regular general meeting as observers and share their views with us.
Structure of joint research
A Tool for Improving the Process
As one of the activities of this research, let me introduce the development of a tool for improving the newbuilding design and building process in cooperation with Oshima Shipbuilding.
First, we have developed a conceptual plan for the tool. As shown in the image, the right side shows the integrated database called “e-SPEC,” which contains information necessary for shipbuilding design. On the left side, a 3D model is shown, which serves to project the information in e-SPEC in a form that is easier to understand. We have decided to call the platform “Basic Design Platform,” or “BDP” for short, and to proceed with its development.
Concept of Basic Design Platform (BDP)
Next, we proceeded to analyze the existing specifications and drawings, and consider establishing the above-mentioned BDP, and identified the important points as follows.
- A ship is a gathering of systems such as “mooring,” “propulsion,” “ballast,” etc., and it is important to be able to confirm specifications on a system basis.
- The information that corresponds to the “design concept” is clear in the shipyard design process, but it is not sufficiently expressed in the existing specifications and drawings, and it is important to be able to visualize this information.
- In the current design process, “repeated work of hypothesis and verification” is the key, and it is important to be able to streamline this process.
We considered that the above issues could be solved by appropriately constructing and utilizing BDP. We then built a BDP prototype for a relatively simple provision handling system and held a virtual specification meeting with Oshima shipyard to verify and confirm this idea.
Conducted virtual specification meeting for provision handling system
Currently, we are continuing to develop BDP and brushing up the concept and prototype. Below is a diagram of the results of our studies to date, and the key points are as follows.
- Organizing overall idea of the future BDP
The overall idea of the future BDP is to link the databases held by each stakeholder through the BDP, so that the industry as a whole will be able to utilize the BDP. At that time, the BDP database and the 3D model would be stored and managed by a third-party organization, such as classification societies. The goal is to achieve a partial operational launch between shipowners and shipyards within the timeframe of this joint research. - Study of 3D model construction methods
By combining design information from existing 3D design tools, the model is built in a way that is as less time-consuming as possible for shipyards. Here we use data output from NAPA, CADMATIC, and MATES. 3D models of compartments, hull, and rigging are combined into a single model, which contains enough information. - Study of database configuration in shipyards
The database for shipyards is supposed to manage the “design” information required by shipyards on the product data management system by dividing it by the ships’ system base (fire prevention, extinguishing, water supply, mooring, etc.). - Study on how to link 3D models and databases / Developing a prototype of interface for negotiations between shipowners and shipyards
We are creating an interface that automatically links “3D models” created by shipyards in the design process with “e-SPEC”. Since this interface confirms the “ship specifications” required by the shipowner side, it picks up and displays the “specification” information required by the shipowner side in the shipyard’s database. Since shipyards’ databases are system-based configurations, it is possible to view information on a system basis. - Preparation for trials of cooperation between shipowners and shipyards
We are preparing for a trial utilizing BDP as a communication tool and plan to discuss work processes when BDP is incorporated into actual business operations.
Results of the study so far
Derived from the above BDP development, we have also started to consider a BDP that utilizes 3D CAD applications. While the BDP of the above-mentioned Oshima shipyard concept is divided into “3D model” and “database,” this concept will add a database function to CADMATIC’s 3D CAD application. We believe this could be an advantage for small and medium-sized shipyards, as they do not need to have their own database.
Another concept in the development of this BDP is to study the diversion of design data from the mother ship. Specifically, we intend to study the “sister ship function,” which is an existing function of CADMATIC tool, and the utilization of module design technology.
BDP concept utilizing 3D CAD application
Deepening the Utilization of 3D Models
I will then explain the other initiative, which is to deepen the utilization of 3D models. As mentioned earlier, we believe that 3D models should be used not only during the design and building phase, but also after the ship has been delivered, and that they should be used for the efficient utilization and feedback of various data after the delivery.
Accordingly, we have created “Digital Finished Plans” for coastal coal carriers built by Honda Heavy Industries. Conventional finished plans are in paper or PDF format, but by digitizing them and improving their convenience, we aim to expand the overall efforts to utilize 3D models. The actual structure of Digital Finished Plans is shown in the diagram below. You can access the corresponding parts of the 3D model from the 2D map, and the “equipment” and “pipes” in the model are linked to the corresponding “drawings”. Furthermore, as it uses CADMATIC e-Share and e-Go as tools, it has a wide range of functions as a 3D CAD application.
Structure of Digital Finished Plans
The main users of Digital Finished Plan are assumed to be ship management companies. Currently, we are working with Asia Pacific Marine Corporation to test and verify the prototype. When we conducted a demonstration for the crew members of the target ship, we received many positive comments, as shown below.
- Piping work can be planned in more detail, improving work efficiency
- Crew members can share their locations/positions with each other
- It could be used for training for crew members before boarding the ship
- It would be useful for sharing information with shipyards and classification societies
Meanwhile, as it has only been a short time since the trials began, we would like to continue improving the functionality of the Digital Finished Plans by asking for comments and feedback after a certain period of use.
Demonstration of Digital Finished Plans’ prototype
Providing Digital Finished Plans (e-Go tablet version) to the chief engineer of the target ship
Future Outlooks
This is all the technical efforts involved in this study, and we will continue to refine the various tools we are developing for actual implementation. Meanwhile, even if this initiative is ultimately realized “between specific shipyards and shipping companies”, we believe it will be less effective. Specifically, if shipyards and shipping companies each build their own individual tools in their own unique way, it could not only be inefficient, but also a burden on the industry as a whole.
Therefore, we are carrying out this initiative through open collaboration. As mentioned in the section on “Structure of Joint Research” at the beginning of this article, the number of companies participating as observers is gradually increasing. NAPA Japan has been very supportive of our efforts, including by proposing and hosting the workshop “Ideal Shipbuilding Design Process”. We will continuously introduce the activities of this initiative.
Workshop related to “Ideal Shipbuilding Design Process” hosted by NAPA Japan
(Oshima shipbuilding, ClassNK, NYK, MTI)