remanufacturing & ship repair possibilities, networking ... · remanufacturing & ship...
TRANSCRIPT
Remanufacturing & Ship Repair
Possibilities, networking and outlook
World Remanufacturing Summit
Shanghai, China December 2nd-4th, 2013
Kim Jansson
VTT Technical Research Centre of Finland
2 10/10/2014
Objectives of the presentation
To study remanufacturing potential in the different types of
ship repair activities.
To analyse different roles of ship repair activities in the
remanufacturing value chain and reverse logistics
operations
To review challenges and opportunities of applying the
remanufacturing concept in the ship repair domain.
To study forms of networked remanufacturing
organisations.
3 10/10/2014
VTT Technical Research Centre of Finland is the biggest multi-technological applied research organization in
Northern Europe.
VTT provides high-end technology solutions and innovation services, to customers and partners.
VTT is a government owned, not-for-profit organisation.
VTT can combine different technologies, create new innovations and a substantial range of world class
technologies and applied research services thus improving its clients' competitiveness and competence.
Turnover: 316 M€ (2012)
Personnel: ap. 3000
VTT in a Nutshell
4 10/10/2014
Background
The goal of the DemaNET-project is to create future preparedness and
knowledge for the Finnish industry about business concepts
and networking models that advance dematerialization, through;
• Remanufacturing,
• Strategic eco-industrial networks,
• Sustainable business models.
Industrial partners:
Valtra, John Deere, Tana, Martela, Turku Repair Yard
Tractors, Forest harvesters, Landfill compactors, Office furniture, Ship repair
5 10/10/2014
Ship Repair Activities
Ship repair yards offer maintenance services to ship owners, so that the ships can be
operated profitably and kept in proper condition in line with (often changing)
• regulations of the IMO (International Maritime Organization),
• their flag states requirements and
• minimum standards of classification societies.
Ship repair does not necessarily imply the need for dry-docking, as work can be undertaken
alongside at berths or at sea.
Ship conversion services alter the structure and/or configuration of vessels in order to enable
them to carry out a different purpose than was originally intended when the vessel was built.
6 10/10/2014
Ship Repair & Remanufacturing
• An industry branch not very often addressed in the
“Remanufacturing” community.
• A complete ship cannot be remanufactured if we interpreted the
definition of Remanufacturing. (R. Steinhilper: Restoring used
durable products to a “like new“ condition)
• There are many forms of ship repair activities: Rebuilding,
Refurbishing, Reconditioning and Overhauling are frequently
used terms in ship repair.
• The principles of Remanufacturing can be applied to small
sections, parts and ship equipment.
7 10/10/2014
Special Characteristics of Ship Repair Business
• Labour intensive, less automation
• Short delivery times
• Planning and scheduling long in advance vs. Ad-
Hoc and unplanned activities
• Intensive short period when the ship does not
“make money”
• Include a variety of skilled labour and partners
• Involve a large variety of products
• Sometimes involve environmentally hazardous
material usage
• Every dry-docking is unique
• One-off ”large” ships, but lots of small
components and work objects
• Conservative business domain
8 10/10/2014
What is ship repair? Milestones of ships Lifecycle Frequency Location
1 Maintenance Continuous Any
2 Small scale voyage repairs Occasionally At sea
3 On-Board repair Occasionally Harbour
4 Planed dry-docking, ship overhaul 2 times in 5 years Repair Yard
5 Large scale Retrofit & Refurbishment After 10 – 15 years
of operation
Repair Yard
6 Modernisation
extend the commercial life with an
other 20 years.
First lifetime is
usually 20 – 30
years
Repair Yard
7 Conversion, Lengthening,
Transformation to other usage
n/a Repair Yard
8 Emergency repair & damage repair
No scheduled All
9 10/10/2014
Special case Passenger ship
Scheduled dry-dockings (duration ~ 2 weeks)
Ship out of service for maintenance
Scheduled Refurbishment (duration ~ 3-4 weeks)
Interior surfaces of passenger public areas
Cabins
Scheduled large Retrofit (duration ~ 3-4 weeks)
Technical features
Safety requirements
Energy savings and emission control
Major conversions
Needed to extend the
commercial with e.g.
20 years
10 10/10/2014
“Standard Remanufacturing Process”
Remanufacturing process
Customer
Remanufactured Products
New Products Alternative usage / waste
Waste
Reverse supply chain
Forward supply chain
Used Products (Cores) Reman. Products
Product
End of Life
11 10/10/2014
Remanufacturing Opportunities Milestones of ships Lifecycle Frequency Location
1 Maintenance Continuous Any
2 Small scale voyage repairs Occasionally At sea
3 On-Board repair Occasionally Harbour
Remanufacturing Company
(OEM & others)
SHIP
Remanufactured Products
New Products Alternative usage / waste
Waste
Used Components (Cores)
Reverse supply chain
Forward supply chain
Other SHIP
The ship is a Core Supplier and customer of remanufactured components
12 10/10/2014
Example: Maintenance, Small scale voyage repairs and
On-Board repair: Potential Remanufacturing Objects
Corrective maintenance, e.g.
Break down maintenance
Spare parts & Component replacement
HVAC systems
but also
Planned maintenance
Predictive maintenance
Preventive maintenance
13 10/10/2014
Milestones of ships Lifecycle Frequency Location
4 Planed dry-docking, ship overhaul 2 times in 5 years Repair Yard
Remanufacturing Opportunities
External Remanufacturing
Company (OEM & others)
Repair YARD
Remanufactured Products
New Products Alternative usage / waste
Waste
Used Products (Cores)
Reverse supply chain
Forward supply chain
Second Life
The Repair Yards acts as Core Supplier and customer of reman. components
Other Yards or Customer
14 10/10/2014
Example “Equipment Remanufacture (OEM)”
Main components for diesel engines:
Cylinder covers
Pistons
Piston crowns
Piston rods
Exhaust valves
Cylinder covers
Connecting rods
(Source: Wärtsilä Inc.)
Second life of special
material and metals
used for e.g. bolts and
rods
15 10/10/2014
Remanufacturing Opportunities Milestones of ships Lifecycle Frequency Location
5 Large scale Retrofit & Refurbishment After 10 – 15 years
of operation
Repair Yard
Internal Remanufacturing or External Company
(OEM & others)
SHIP
Remanufactured Products
New Products Alternative usage / waste
Waste
Used Products (Cores)
Reverse supply chain
Forward supply chain
Cores can be collected from the Ship. The Yard can acts as remanufacturing company
Other SHIP
16 10/10/2014
Example “Cabin Refurbismsnet”
“Remanufacturing of a complete cabin” (Restoring to a “like new“ condition)
“Remanufacturing of cabin components”
Cabin refurbishment projects can include:
Reupholstery of soft goods
Textiles (sheers, draperies, head boards etc.)
Refinishing of fixed furniture
New wall, floor and ceiling surfaces
Bathroom floors and walls
Bathroom furniture and fittings
Technical (electrical, HVAC, piping etc.)
(Source: I-S Makinen, Inc.)
17 10/10/2014
Remanufacturing Opportunities Milestones of ships Lifecycle Frequency Location
6 Modernisation
extend the commercial life with an
other 20 years.
First lifetime is
usually 20 – 30
years
Repair Yard
7 Conversion, Lengthening,
Transformation to other usage
n/a Repair Yard
External Company (OEM & others)
SHIP
Remanufactured Products
New Products Alternative usage / waste
Waste
Used Products (Cores)
Reverse supply chain
Forward supply chain
Cores can be collected and remanufactured for other usage
Other usage
18 10/10/2014
Summary Remanufacturing in Ship Repair Milestones of ships
Lifecycle
Reman.
Opportunity
Role of Ship
(Ship Owner)
Role of Repair
Yard
1 Maintenance Yes Core supplier n/a
2 Small scale voyage repairs Yes Core supplier n/a
3 On-Board repair Yes Core supplier n/a
4 Planed dry-docking, ship
overhaul
Yes Customers of
reman parts
Core collection,
Prepare 2nd life
5 Large scale Retrofit &
Refurbishment
Yes Customer of
reman parts
Remanufacturer
6 Modernisation
extend the commercial life
with an other 20 years.
Minor Core supplier Core collector
7 Conversion, Lengthening,
Transformation to other usage
Minor Core supplier Core collector
8 Emergency & damage repair n/a n/a n/a
19 10/10/2014
Challenges and Opportunities of Applying
Remanufacturing in Ship Repair
Challenges
Few standard products
The uncertain timing and quantity of
returns
Reverse logistics: from different locations.
Small quantity of products collected from
each source
Difficulty in achieving an economy of
scale
Employees' knowledge and skills in
remanufacturing
Finding a suitable customers (ship) for
used parts
Opportunities
Ships series, sister ships
Big ships, more similar components
Partnership with OEMs for
Components and systems
Upgrade technology
Response to environmental
legislation
Better reputation, attract workforce
Growing markets
20 10/10/2014
The Role of a Repair Yard in the Remanufacturing Network
Disassembly /
Core collection
Repair Yard
Transport Recycling
or disposal
Transport External
Reman.
Internal
Repair or
Reman.
Assembly and
Testing
Other
Customers
“2nd life-cycle”
“Like new”
Transport
21 10/10/2014
Growing Markets
The number of seagoing vessels continuously increase.
Ship repair is a permanent element in the maritime industry. Always needed.
Periodic and emergency maintenance and repair work are essential to keep
vessels operable.
All vessels must also undergo special surveys every five years in addition to
regular repairs for them to remain seaworthy.
Economically, many ship owners have found it more profitable to increase the life
of their existing fleet due to the high building costs of a new vessel. The results
are increased surveys and repair work for the yards.
Environmental issues raised by accidents and oil spills put pressure on ship
owners to improve maintenance standards.
In all - There is positive outlook for the ship repair industry.
22 10/10/2014
Scheduled repair demand estimate (2007-2015) Source: Worldyards (2007)
23 10/10/2014
Conclusions
Remanufacturing & Ship Repair
Include many of the same challenges as in remanufacturing in
other industry branches
The principles of remanufacturing can be included as a part of the
much larger ship repair process
Need networking
Increasing market
Large opportunities for sustainability innovations
Repair Yard and Ship Owners need to be active, introduce new-
thinking in a conservative business domain
24 10/10/2014
This is what we want to decrease & avoid
25 10/10/2014
Thank You for Your Attention!
Questions?
Contact:
Kim Jansson
VTT Technical Research Centre of Finland
Tekniikantie 2, Espoo
P.O.Box 1000, FI-02044 VTT, Finland
Tel. +358 50 5457989
26 10/10/2014
VTT creates business from technology