AVEVA World Magazine 2013|Issue 137Tailored for SuccessHow an optimised AVEVA MarineT deployment exceeded expectations at Kyokuyo ShipyardJanis ChoiSenior Marketing Specialist, AVEVAOne of Japan's innovative medium-sized shipbuilders, the Kyokuyo Shipyard Corporation recently upgraded their engineering and design system to AVEVA Marine with considerable success. We invited Mr Hiromasa Yamamoto, Assistant Chief, Production Design Department at Kyokuyo, to share their experiences of the implementation.Kyokuyo builds a wide variety of vessels. Its main product lines are high-specification container carriers and refrigerated cargo carriers, but it also builds complex, high-value vessels such as liquefied gas carriers, cement carriers and roll-on/roll-off ships. It was demand for these more complex classes of ship that led to the company expanding its production capacity with the addition of a new block assembly hall and the lengthening of its dry dock.However, increasing the yard's physical capacity highlighted the need to upgrade its design software from the original 2D drawing-based system to a modern 3D solution. Like many other engineering businesses using 2D, its designers found limitations in clash detection and incomplete information for fabrication and construction. These often led to costly rework through having to make late design modifications. Kyokuyo also faced the global challenge of replacing a retiring workforce of experienced engineers and designers. It needed a solution which would not only overcome the inherent limitations of 2D design, but would meet the specific needs of shipbuilders and be easier for a new generation of younger designers to use. After extensive evaluation, the company selected AVEVA Marine.Changing such a vital element of the business as the design system can potentially be very disruptive, so Kyokuyo adopted a cautious approach, planning to deploy the new system progressively while maintaining the use of the 2D system. Regular readers will perhaps not be surprised that the project was completed much more quickly than anticipated and with little or no disruption to the business.With support and training provided by AVEVA's Yokohama office, AVEVA Marine was implemented at Kyokuyo Shipyard in April 2010. AVEVAT consultants worked closely with Kyokuyo's engineers to configure and optimise the production information to suit the shipyard's workshop facilities.Kyokuyo Shipyard located in Shimonoseki in Japan. Photograph courtesy of Kyokuyo Shipyard.
38AVEVA World Magazine 2013|Issue 1After a week's on-site hull and outfitting training, designers began work on a pilot project, with further training conducted as need arose. The pilot project proved very successful and was completed much earlier than originally planned. Kyokuyo's design team were then fully able to tackle their first live project in AVEVA Marine, a container carrier for a Chinese owner, which started in May 2011. At the time of writing, Kyokuyo have designed and built two ships entirely using AVEVA Marine and delivered them on schedule. Both carriers are suited for Japan - China - Korea trade.Achievements and benefitsThe success of the upgrade project considerably exceeded Kyokuyo's expectations. The combination of AVEVA Marine's ease of use and tailored on-site training enabled hull and outfitting designers with no previous experience in 3D software to quickly become proficient users. The implementation was achieved quickly and the new system completely replaced the old 2D system, even down to configuring AVEVA Marine's drawing outputs to the yard's established formats. Mr Yamamoto explained, 'We were certainly unnecessarily cautious when we planned the implementation. It was far easier and quicker than we ever imagined, and could have been even quicker; the timetable was largely imposed by the specific schedules of the projects going through the yard at the time.'It was not only the speed and ease of implementation that impressed Kyokuyo; the practical benefits also exceeded expectations. 'Simply moving from 2D to 3D design brought us massive benefits,' commented Mr Yamamoto. 'It saves our engineers a lot of time and effort. With a design team of 28, just trying to share and control information had been difficult and absorbed a lot of man-hours which could be better used. AVEVA Marine has given us much more efficient working methods which translate into quicker delivery of better quality ships.'Moving to 3D has made efficient concurrent working possible, a key requirement for Kyokuyo. All engineering and design disciplines can now work on the same 3D ship model, using the same component catalogue. Kyokuyo now finds it easier to create the design more quickly and to manage the large quantities of data generated. Design reviews are quicker and more thorough, and can involve all engineering groups, including construction.The production stages benefit considerably. Accurate and complete production information can now easily be retrieved direct from the 3D ship model. AVEVA Marine also integrates efficiently with Kyokuyo's other IT systems, including its purchasing and materials systems.OpportunitiesSuch a comprehensive upgrading of an essential business system inevitably reveals opportunities for further improvement, either within the customer's own business processes or in the software itself. Mr Yamamoto said, 'We found many unexpected opportunities as a result of this upgrade. The information created in design can now be used for many more purposes to make the entire project more efficient. For example, trying to coordinate materials, planning and construction with the design was previously a difficult and largely manual process. We have made big improvements here already.'Until we experienced it for ourselves,' continued Mr Yamamoto, 'we also had not appreciated the value of being able to "walk" through the virtual ship. Now our designers can see and eliminate design problems long before we begin to cut steel.'The futureMr Yamamoto is enthusiastic about the part that AVEVA Marine will play in the future of Kyokuyo Shipyard. 'It more than met our expectations,' he explained. 'The ease of configuration means that we will be able to adapt the system as our business develops. Not only has it made us more efficient and competitive, it also enables us to demonstrate our capabilities more easily. The 3D ship models are ideal for review meetings with the ship owners, and make excellent marketing material to demonstrate our portfolio of ships that we can build.'At Kyokuyo Shipyard in May 2012. From left, Mr Aiba, Manager, Fundamental Design Department at Kyokuyo, Mr Hiromasa Yamamoto, Assistant Chief, Production Design Department at Kyokuyo, Mr EunJoo Park, Senior Vice President, AVEVA Korea-Japan Division and Mr Motoo Iso, Country Manager Japan, AVEVA Korea-Japan Division. Photograph courtesy of Kyokuyo Shipyard.'AVEVA Marine has given us much more efficient working methods which translate into quicker delivery of better quality ships...'