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Page 1: ketmaritime.euketmaritime.eu/.../2019/10/...Manufacturing-Shipbuilding-Applicati..…  · Web viewcase studies on kets marine applications. case 1. advanced manufacturing shipbuilding

Copyright © 2019 IDONIAL Technology Center

CASE STUDIES ON KETs MARINE APPLICATIONS

CASE 1

ADVANCED MANUFACTURING SHIPBUILDING APPLICATIONS

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Index1. INTRODUCTION........................................................................................................................3

2. CONTEXT OF THIS DOCUMENT..............................................................................................3

3. METHODOLOGY........................................................................................................................4

4. ADVANCED MANUFACTURING KET OVERVIEW...................................................................4

4.1. Advanced Manufacturing Main Applications........................................................................5

5. EU Strategy on Advanced Manufacturing...................................................................................7

6. ADVANCED MANUFACTURING KET MARINE APPLICATIONS (SHIPBUILDING)..............11

6.1. Digital Manufacturing Technologies...................................................................................11

6.1.1. 3D design for Early Stages and Other Trends............................................................11

6.1.2. Simulation Technologies............................................................................................14

6.1.3. 3D Scanning...............................................................................................................16

6.1.4. 3D Printing..................................................................................................................18

6.2. Automation.........................................................................................................................22

6.3. Simulation and Immersion Technologies...........................................................................25

6.4. ICT and Digitalization.........................................................................................................28

7. LOOKING TO PATENTS TO MEASURE ADVANCED MANUFACTURING RELEVANCE.....29

8. CONCLUSIONS........................................................................................................................32

9. ANNEX: Representative Advanced Manufacturing for Shipbuilding Patents...........................35

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1. INTRODUCTIONAdvanced manufacturing is a broad concept that houses the application of the latest technological advances to the productive field, leading to optimizations in processes, reductions in costs and impacts, and improvements in the quality of the resulting products. These advances have resulted in the evolution to its progressive maturity of technologies such as 3D scanning, 3D design, 3D printing, artificial vision, virtual and augmented reality, flexible and collaborative robotics, the simulation of production processes, the evolution of communication technologies, etc. As a manufacturing industry, shipbuilding can benefit from the implementation of many of these technologies, promoting a technological change that can increase the competitiveness of the organizations working in the sector. Thus, this document tries to act as a brief compendium of some of the main advantages that for shipbuilding activities lie within the implementation of advanced manufacturing, through providing an approach to some of the main technologies involved.

2. CONTEXT OF THIS DOCUMENTThe present document constitutes a deliverable in the framework of the KETmaritime project “Transfer of Key Enabling Technologies (KETs) to the Maritime Industries”. This document is the result of the activities performed within the Action number 3 “Scientifical and Technical Analysis: State of the Art and technology trends revision”, within the framework of WorkPackage 5 (WP5), titled “Mapping of R&D ecosystem”. Action number 3 is intended to generate five case studies related to a KET – sector/subsector combination. For each case, a technology study is performed by searching information in existing reports, scientific publications and patent databases in order to determine current state of technologies, stakeholders, technology trends, etc. The five case studies selected are shown in the next table:

Table 1: KETmaritime case studies – Scientific and Technical analysis (WP5, Action 3)

ID KET Title

1 Advanced Manufacturing Advanced Manufacturing Shipbuilding Applications

2 Nanotechnology Nanotechnology Marine Applications

3 Industrial Biotechnology Marine Industrial Biotechnology

4 Photonics Photonics Marine Applications

5 Micro and Nanoelectronics Microelectromechanical Systems (MEMS) Marine Applications

This document is related to Case Study 1 – Advanced Manufacturing Shipbuilding Applications.

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3. METHODOLOGYThis document will address the previously presented subject through the following sections:

- Advanced manufacturing Key Enabling Technology overview : brief description of the main involved technologies and basic principles, also providing information about general applications. An overview of European Strategies for R&D related to this KET is as well provided.

- Advanced manufacturing Shipbuilding applications : a state of the art addressing applications of this KET in the shipbuilding activity.

- Brief study of patents in the field of the application of advanced manufacturing technologies to shipbuilding.

- Final conclusions : summary and highlights of the document.

4. ADVANCED MANUFACTURING KET OVERVIEWFar from being univocal, advanced manufacturing is a broad concept, which instead of being identified with a specific technology, is associated in a general way with the incorporation of innovative technologies to the manufacturing processes, with the purpose of making these processes more agile, flexible and efficient. In this way, it can be said that advanced manufacturing is not so much a concept of our time, as a timeless concept, that in each moment embraces current innovative technologies.

That said, in our days advanced manufacturing is strongly influenced by the intense technological development experienced in recent years on several fronts, mainly in the fields of digital manufacturing, ICT (Information and Communications Technology) and automation. All these technological advances come together nowadays, giving rise also to the emergence of concepts such as industry 4.0, aimed at marking a turning point for the industry in the way to a complete digitalization.

Currently, advanced manufacturing is associated with the incorporation into the manufacturing processes of, at least, the following technologies:

- Digital manufacturing technologies : tools for design, simulation, engineering, manufacturing, 3D scanning and 3D printing, etc. The progressive digitalization of design, engineering and manufacturing activities has been greatly enhanced by the proliferation of different technologies, capable of reproducing geometries without the need to previously go through a “classical” design and engineering process (3D scanning), and to produce parts just from a 3D file by successive layering manufacturing (3D printing).

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- ICT Infrastructures, technologies and services : wireless networks, mobile devices, cloud

computing, low cost development hardware, closs-plattform programming languages, wearables, software as services, etc. The rapid progress experienced in the last 20 years in the fields of internet, software, hardware and mobile technologies enables a real-time management of manufacturing activities, from any point of the world, at any time.

- Automation : AI (Artificial Intelligence), neural networks, collaborative robotics, artificial vision, robots and autonomous vehicles, etc. Robotics and automation is marked in the present by the ability of autonomous systems to communicate and interact in complex networks, made up of other robots and humans. In the same way, the proliferation of autonomous devices provided with vision and positioning systems (drones, land and air vehicles, marine and submarine vehicles, etc.) are called to increase operations efficiency on every sector.

- Simulation and Immersion technologies : virtual reality and augmented reality. The recent emergence of affordable technology for the development of virtual and augmented reality applications is giving rise to a large number of possibilities, in areas such as the design and optimization of productive processes, the training of people, or the assistance to operators through overlapping (in the own field of view of an operator or in a display device) additional information.

The previous technologies present, despite their differences, two important common points:

- These technologies are approaching (or have already reached) a point of technological maturity and affordability that allow practically any type of activity and organization to take advantage of them.

- The level of complementarity of these technologies is very high, leading to a scalable implementation.

It is for all the above that, today, more than ever, "advanced manufacturing" is a concept of high relevance, since it houses all the technologies that are currently key to the competitive improvement of different industrial areas.

4.1. Advanced Manufacturing Main ApplicationsAlthough as previously described advanced manufacturing it is a truly wide concept, and therefore difficult to fully comprehend in a document such as the present one, it is possible to do a brief depiction of is applications:

- Digital manufacturing technologies . The transition from 2D to 3D design and engineering processes, together with the strong emergence of 3D printing and scanning technologies, allow to face manufacturing in a substantially different way. Digitalization contributes to a great increase in the speed of the processes of design, manufacturing and evaluation of prototypes, reducing fixed costs (3D printing makes ancillaries unnecessary) and ultimately increasing flexibility and speed to the overall process.

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Thus, and to give some examples, in each of the steps that lead to the development of a product, these technologies can lead to the following operational advantages:

o Design and engineering . The distinguishing feature of digital manufacturing technologies at this stage of product development is that, given the freedom of design they provide, and the speed and ease with which these technologies can be applied, they reduce the technical, time and cost restraints associated with traditional technologies.

o Prototyping and testing . Digital manufacturing technologies allow the manufacturing and testing of functional prototypes (scaled down or actual size prototypes, depending on the application). The advantage at this stage is again the elimination of the limitations of other technologies, allowing a shorter manufacture time and a rationalization of the costs involved.

o Final parts manufacturing . Compared with traditional manufacturing technologies, which require high initial investments (moulds, ancillaries, etc.), digital manufacturing technologies can produce the first series of parts/products without the need for any additional investments beyond the additive manufacturing technology itself. In other words, (provided that these technologies can be technologically capable for a selected case) these technologies are more economical until the moment/volume of units that allows the amortization of the investment required by traditional technologies is reached. From that point, the optimization associated with these traditional technologies usually offer a lower unitary cost.

- ICT Infrastructures, technologies and services . The advances in hardware and communications, as well as the progressive adaptation of the main productive resources to connected environments, lead to the development of new concepts of production processes and plants, in which all the information generated in the plant can be exploited and used to increase the operational performance, through implementations such as the following:

o Adaptative and flexible planning . When all the productive resources are connected to an integrated information system in an industrial plant, it is possible to implement advanced decision systems that make use of the information in real time, making it possible to adapt the level of performance of the plant and anticipate difficulties. The development of algorithms and their integration into planning softwares (often known as MES, Manufacturing Execution Systems) will also not only provide information of high relevance, but also implement automations that facilitate the interpretation of information and decision making.

o Optimization of preventive maintenance . Sensorization technologies have led to devices capable of monitoring the "vital signs" of each equipment, such as, for example, the maintenance status of the spindle of a machining centre, based on the frequency profile of the sound generated by the turn of the same. These types of implementations are possible today, based on the existence of a wide range of sensors (temperature, sound, visual, etc.) that can lead to the detection of

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malfunctions in a preventive way, before a breakage can stop and harm the production.

o Remote monitoring . The introduction into the productive environments of communication systems (wired or wireless) allows access to plant information from any point and at any time, facilitating decision making, especially in highly flexible environments.

- Automation . Although robotics is a discipline that already accumulates a considerable experience in relation to its implementation in repetitive tasks, the current concept of automation is really much broader, including relevant fields like the next ones:

o Collaborative robotics . Implementation of collaborative robots in critical activities and complex work sequences, in which collaboration between robots or between robots and human beings is demanded.

o Adaptative and autonomous robotics . Development of sensory, vision and perception systems, algorithms and intelligence networks capable of increasing the autonomy of robots to operate unattended in a flexible manner, without risks to human beings.

o Quality control . Automation of measurement and verification tasks thanks to the implementation of sensors and vision systems for the implementation of on-line and off-line control systems for non-compliant products.

- Simulation and Immersion technologies . Although the concepts of simulation, virtual reality and augmented reality are not new, it is at present time when the technologies for their implementation have reached a sufficient degree of maturity and accessibility to allow various kinds of applications:

o Simulation of plants and manufacturing environments . The ability to digitally recreate a new or existing work environment provides the ability to simulate operations without the need to consume productive resources, this being a "testing ground" for the evaluation of variants and production alternatives in complex processes.

o Virtual and augmented reality . The possibility of “immersing” in a virtual recreation of a plant or productive process (virtual reality) or the possibility to add virtual layers of information on the field of vision of a person (augmented reality) constitute high-level capabilities for the productive field.

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5. EU Strategy on Advanced ManufacturingDuring the last two decades, both the European Platform for Advanced Manufacturing (MANUFUTURE1) and the private sector trough specific PPP´s (Public-Private Partnerships), as well as the European Commission through its support for Innovation in the past FP6 and FP7 schemes, have sponsored and developed road maps and strategic agendas that have served as a guiding element for European manufacturing in the 21st century. Currently and within the “umbrella” of Horizon 2020 Framework Programme2, most of the strategies and roadmaps have culminated in what is known as the PPP Factories of the Future3, which currently marks the thematic priorities for the development of European manufacturing, and that based on a significant financial allocation (1.15 billion €) articulates within its framework a roadmap characterized by the following main points:

- Challenges and opportunities . The current roadmap (2014-2020) focuses on the economic, social and environmental sustainability of manufacturing, combining aspects such as flexibility, adaptability and reconfigurability for small-scale processes, the entire management of the cycle of life of the products, the promotion of manufacturing as an attractive field for labour development, the efficient use and re-use of resources, and the reduction of emissions from industrial processes.

- Priorities . Previous challenges and opportunities, in combination what the roadmap denominates “technologies and enablers”, lead to the definition of six fields of action:

o Advanced manufacturing processes . Under this field a series of subpriorities are included, which among other aspects include tailor-made manufacturing, multi-material bonding, surface processes, micro- and nano-scale manufacturing, life cycle management, optimization of supply value chains, etc.

o Adaptative and Smart Manufacturing Systems . This priority is focused on providing the systems with flexibility and adaptability, with an emphasis on robotics and its interactions with humans, mechatronics, microfabrication, connectivity, etc.

o Digital Virtual and Resource Efficient Factories. This priority also includes advances related to evolutionary manufacturing systems, intelligent maintenance systems, monitoring and optimization of energy consumption, the integration of simulation and analytical tools, the design and management of manufacturing strategies, etc.

o Collaborative and Mobile Enterprises . This priority places its focus on the capabilities provided by modern communication technologies: supply networks, cloud storage, collaborative demand and supply planning, digital rights management, mobile applications for agile management, etc.

1 http://www.manufuture.org/

2 https://ec.europa.eu/programmes/horizon2020/en

3 https://www.effra.eu/factories-future

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o Human-Centred Manufacturing . This priority is associated in a basic way to how the human being can adapt to advanced technology, and as in turn can be supported by it, contemplating progress in the definition of learning methods, adaptation of jobs, plug and play interfaces, improved information visualization for workers, technological demonstrations that increase the interest of manufacturing for new generations, etc.

o Customer-focused Manufacturing . This last priority puts the customer as the central axis of Innovation, and based on it articulates sub-priorities aimed at increasing adaptability and communication capacity with customers.

Figure 1: Factories of the Future PPP Roadmap Framework4

In the present cycle this roadmap is reflected in the 2018-2020 work programme "Nanotechnologies, Advanced Materials, Biotechnology and Advanced Manufacturing and Processing", which in its call "Transforming European Industry" develops an innovation action called Factories of the Future, which includes said a series of topics in line with the described roadmap:

4 https://www.effra.eu/sites/default/files/factories_of_the_future_2020_roadmap.pdf

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Figure 2: H2020 Nanotechnologies, Advanced Materials, Biotechnology and Advanced Manufacturing and Processing Work Programme 2018-2020: section Factories of the Future5

In light of the above (and although this does not imply a detailed review of all the existing tools, but of the most relevant ones), it is clear that at European level there is a support structure for the development of advanced manufacturing and its application to the different sectors.

5 http://ec.europa.eu/research/participants/data/ref/h2020/wp/2018-2020/main/h2020-wp1820-leit-nmp_en.pdf

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6. ADVANCED MANUFACTURING KET MARINE APPLICATIONS (SHIPBUILDING)

6.1. Digital Manufacturing Technologies

6.1.1. 3D design for Early Stages and Other TrendsAlthough tools for 3D design and engineering have existed for a long time, a large part of the design processes involved in shipbuilding still take place in 2D for many organizations, especially in early stages of design6. The above has been due historically to a simple effort-cost relationship, because although the 3D design from the initial stages represents a series of advantages (which we will present later), shipbuilders still find in 2D design tools a very agile way to make estimates and to quick launch projects.

3D design tools have existed for more than 3 decades, so their capabilities have reached a considerable maturity, which allows an identification of some main advantages over 2D design7:

- Visualization and assemblies . Due to the ability to see any element in 3D, and these elements being a part of assemblies of great complexity, it is possible to detect conflicts in the fit of elements, not visible by direct means in 2D processes.

- Because of the above, the cost of design changes when a 3D design process is used is considerably lower, since the corrections are made directly on the affected elements. This means that in general, the design processes fundamentally based on 3D design software are more agile, especially when the product as a whole is highly adapted to the client's specifications.

- On the other hand, 3D design clearly facilitates integration with other technologies that also start from a 3D file, such as technologies for structural simulation or 3D printing technologies, being also the "language" for measurement and verification technologies based on 3D scanning.

6 A next-generation of 3D CAD tool for basic ship design. Rodrigo Pérez Fernández and Verónica Alonso de los Ríos, SENER, Ingeniería y Sistemas. 2015. https://sectormaritimo.es/wp-content/uploads/2016/01/301.pdf

7 2D vs 3D CAD: What You Need to Know. Cad Cword. https://www.cadcrowd.com/blog/2d-vs-3d-cad/

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Figure 3: 3D reproduction of the HOTLO diesel engine, from the Dutch company Royal Machine Manufacturing – Stork Bros. & Co., used during 50´s and 60´s decades. Image8 by Isookzo, under Creative Commons Licence Isookzo CC BY-SA 4.0.

However, despite this, many of the design processes involved in shipbuilding still take place in 2D for many organizations, especially in early stages of design. The above is due to a simple effort-cost relationship, since although the 3D design from the initial stages represents advantages such as those described, shipbuilders continue to perceive 2D design today as a very agile way of making first approximations to the design of a ship. In these cases, although later stages would be able to incorporate 3D tools, its beginning as a 2D process introduces a series of technical uncertainties and later inefficiencies (due to the later detection of errors and the resolution of the same ones), that the use of a 3D design process could mitigate.

In this sense, during the last years 3D CAD tools have evolved, and today, as it is treated in the article "A next-generation of 3D CAD tool for basic ship design"9, these tools have functionalities that simplify and automate the work of 3D design in those early stages, increasing the competitiveness of these tools. The referred article is a good example of the capabilities of these tools at the present time for these first stages of design, since, starting in this case from a specific system for shipbuilding (FORAN, from Spanish Engineering SENER), shows the capabilities of the same along different stages of the early stage of design (surface definition and naval architecture calculations, volume definition, hull structures basic design, main equipment positioning and outputs), depicting what could be a general working procedure for shipbuilders using 3D tools.

There are also other trends that are worth to be highlighted within the current paradigm of advanced manufacturing in shipbuilding, with perhaps one of the most outstanding being the introduction of the PLM concept ("Product Lifecycle Management") through specific software. PLM is an information management system that seeks to structure all the information of the organization based on the product, logically organizing all information, processes and activities of the organization. From a software point of view, the PLM is in some way the evolution of the first information management systems around the design work with 3D CAD tools, which later evolved to become the tools known as PDM (product data management), created as a management framework for the entire product information, and which in turn gave rise to the PLM, which also incorporated the ability to manage additional layers of management over the products and related 8 https://commons.wikimedia.org/wiki/File:HOTLO_nr8599_reconstructie_in_Solidworks.jpg

9 A next-generation of 3D CAD tool for basic ship design. Rodrigo Pérez Fernández. Universidad Politécnica de Madrid 2015. https://sectormaritimo.es/3-01-a-next-generation-of-3d-cad-tool-for-basic-ship-design

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processes. Thus, PLM (PLM software) is embodied in the organization through specific software, capable of providing the framework for all stages related to the product from its very conception. In essence, the PLM solutions allow a complete characterization of the product and all its elements throughout the different stages of development, in a collaborative environment in which the main advantages are not only reduced to the management of information around a structure and completely digital environment, but it is also collaborative and therefore facilitates the management of the processes associated with an entity that can be as complex as a ship.

Figure 4: PLM software from Siemens. Image10 by Siemens PLM software under Creative Commons Licence CC BY-ND 2.0

PLM is a highly relevant concept for the current shipbuilding business, which is characterized by giving rise in general to a product of great variability and customization, where it is no longer common to manufacture "sister ships" and the degree of reuse of information between ships has been progressively decreasing. In this context, the search for design and manufacturing philosophies aimed at maximum efficiency and use of pre-existing information (it is recommended to see the 2017 thesis "3D Reuse in PLM for Conceptual Ship Design"11) becomes critical, and that is the reason why working with systems based on this PLM philosophy provide shipbuilders with solutions that improve competitiveness. In the shipbuilding sector, PLM tools are being incorporated in a progressive manner, being tools already implemented by leading organizations worldwide, such as Hyundai Heavy Industries Shipbuilding12, Mitsubishi Heavy Industries13 or Ulstein.

10 https://www.flickr.com/photos/31274959@N08/6238422521

11 3D Reuse in PLM for Conceptual Ship Design. Bjørn Tornes. Norwegian University of Science and Technology. 2017. https://brage.bibsys.no/xmlui/bitstream/handle/11250/2462443/Tornes%2c%20B.%202017.pdf?sequence=1&isAllowed=y

12 World’s largest shipbuilder creates first digital shipyard environment to improve productivity in Korea. https://itcr.hr/wp-content/uploads/2014/07/Siemens-PLM-Hyundai-Heavy-Industries-shipbuilding-cs-Z8.pdf

13 MHI’s Nagasaki Shipyard uses PTC Windchill® to Standardize Processes and Manage All Development Data. http://images.connect2communities.com/pdf/j1364_mhi_cs_v3.pdf

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6.1.2. Simulation Technologies

The existing simulation technologies cover different aspects of the shipbuilding activity, in such a way that at the same time that there are tools for the simulation of stresses and deformations (that allow to design, dimension and optimize structures and elements), there are other tools with the ability to simulate productive processes, that facilitate the design and reconfiguration of plants and the optimization of internal flows. In this section we will focus on the second group of applications, due to its great relevance within the concept of advanced manufacturing.

Figure 5: Propeller Finite Element Analysis Data. Image14 by CDC Catia under public domain.

The high competition that the emerging markets (especially the Asian one) is posing to the traditional actors in the field of shipbuilding is causing a necessary adaptation of the activity in the western shipbuilders, who among others have the need to maximize the efficiency of their productive processes to maintain its competitiveness. In this sense, and not only in the field of shipbuilding, there are simulation softwares15 for industrial processes (Quest, Flexim, Promodel, Area, etc.) capable of modelling the productive processes of the organization, implementing them in a virtual environment, in the search and testing of optimizations. Although these tools are not considered as packaged solutions for a specific sector or activity, they include all the necessary functionalities to characterize and model any type of productive activity, so once the core of an activity is modelled, it is possible to define and simulate different situations, introduce modifications, or "put to the test" the system. In this way, there are numerous works that analyse the possibilities of applying these tools to shipbuilding; some works of interest are the following ones:

- "Applying digital manufacturing technology to ship production and the maritime environment”16 analysed already in 2002 the introduction of the concept of simulation based

14 https://commons.wikimedia.org/wiki/File:Fax_1.jpg

15 La simulación de procesos industriales: clave en la toma de decisiones para procesos de reingeniería de planta y diseño de nuevas instalaciones de fabricación. Federación de Empresarios del Metal y Afines del Principado de Asturias. 2010.

http://www.femetal.es/ckeditor_assets/attachments/344/la_simulacion_de_procesos_industriales.pdf

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on the existing software at that time, showing that it was possible to model tasks such as the erection of blocks.

- In 2009, the article "Research on a simulation-based ship production support system for middle-sized shipbuilding companies"17 focused on the development of a simulation environment aimed at small and medium-sized shipbuilders. This article shows how a simulation could constitute for these organizations a framework for the standardization of information necessary to manage production and to adapt planning.

- In 2011 the article "Discrete Event Production Simulation in Shipyard Workshops"18 analysed different process simulation software from the perspective of its application to shipbuilding, through the comparison of 5 different software (ARENA, FLEXIM, PLANT SIMULATION, PROMODEL and QUEST) around a specific case study, the production of three "sister" LNG carriers of 220,000 m3. Among other aspects, this work concluded that the simulation models developed allowed to evaluate the effects of different productive alternatives, while leading to more efficient manufacturing strategies.

- More recently and already in industrial areas, the main Spanish shipbuilder, Navantia, concluded in 2016 an application study of the industry 4.0 concept to shipbuilding19, which served to develop a simulation model that was tested in three cases20,21:

o Definition of optimized production planning.o Detailed analysis of cutting and welding shops.o Analysis of maximum capacity of the line panel.

16 Applying digital manufacturing technology to ship production and the maritime environment. H. KIM*, S.-S. LEE, J. H. PARK and J.-G. LE. Korea Research Institute of Ships and Ocean Engineering/

https://www.researchgate.net/publication/238325620_Applying_digital_manufacturing_technology_to_ship_production_and_the_maritime_environment

17 Research on a simulation-based ship production support system for middle-sized shipbuilding companies. Young Joo Song, Jong Hun Woo, Jong Gye Shin. Research Institute of Marine Systems Engineering, Seoul National University, Seoul, Korea. 2016. https://www.sciencedirect.com/science/article/pii/S2092678216303855

18 Discrete Event Production Simulation in Shipyard Workshops. Jean-David Caprace, Roberto Moreira Freire, Luiz Felipe Assis, Philippe Rigo. University of Liege and University of Rio de Janeiro. 2011.

https://www.researchgate.net/publication/258834989_Discrete_Event_Production_Simulation_in_Shipyard_Workshops

19 Navantia’s Shipyard 4.0 model overview. Ángel Recamán Rivas. Navantia. 2018.

https://www.researchgate.net/publication/324024001_Navantia's_Shipyard_40_model_overview

20 Shipyard 4.0: The Ferrol Navantia Shipyard Model for Planning in Shipbuilding. Alejandro García del Valle, Marcos Rouco Couzo, Mar Cebral Fernández, Marta Quiroga Pazos. Navantia and Universidade da Coruña. 2017.

http://www.gii.udc.es/img/gii/files/agvalle_2017_Shipyard4.pdf

21 APPLICATION OF A MULTI-LEVEL SIMULATION MODEL FOR AGGREGATE AND DETAILED PLANNING IN SHIPBUILDING. Mar Cebral Fernández, Diego Crespo-Pereira. Navantia and Universidade da Coruña. 2017.

https://www.extendsim.com/images/downloads/papers/mfg-shipbuilding.pdf

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In all three cases, the developed model showed its usefulness, as it served as a mean to detect bottlenecks, and optimize the planning of time and resources for productive activity, being an experience of special interest.

On the other hand, and although simulation technologies have great potential, the development of the models is complex, since these simulations start from an initial modelling process that demands relevant works for a general definition of workflows, data collection, standardization of information and establishment of the specific objectives of the simulation. So to speak, and while the particular and progressive development of simulation environments for organizations and specific cases can give rise to powerful tools, nowadays there are no tools with simulation environments specifically pre-defined for all the range of shipbuilding activities. In addition, these simulation environments reach their full potential when they are also integrated into digitalized product management systems (3D CAD, PDMs, etc.,) where the maximum reuse of the already existing assets and the acquisition of information by these environments are greatly facilitated.

6.1.3. 3D ScanningThe fusion of laser scanning technologies (especially portable ones) with the modern capabilities of 3D modelling tools, provide nowadays an unprecedented capacity for rapid capture of dimensional information. Besides, it has to be taken into account the vast possibilities that arise when integrating these technologies with virtual and augmented reality technologies, in which 3D scanning is a basic step for the digital replication of environments and operational elements.

Thus, when establishing the most obvious applications of this technology, the following ones can be identified:

- Dimensional verification during manufacturing . Being the main capacity of these technologies the "extraction" of a cloud of points capable of characterizing a 3D element, the possibility of making measurements "on the fly" or doing a later processing of said information is very valuable, and not only to verify the adjustment to tolerances of independent elements, but to be able to make adjustments in the manufacturing and assembly processes. In this sense and to give just one example, during the assembly process an item could be received, that due to its characteristics (weight, transport, cost), and not yet being 100% according to the original specifications, is so relevant that its substitution could cause an important setback in planning. By performing a 3D scan of this component it would be possible not only to measure it, but to extract a 3D model that could be used as input to a process of review and modification of the complementary elements not yet manufactured and assembled, allowing a quick adaptation of the productive process.

- Documenting . The number of elements integrated in a single ship is such that the documentation of the configuration of these elements once integrated can only be done with the support of technologies capable of quickly characterizing them. This is possible with 3D scanning technologies, which open the door to documentation of various sections of the ship, with special applicability to subsequent tasks of monitoring, maintenance and verification.

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- Maintenance and verification . 3D scanning technologies can be of great help in the tasks of verification and scheduled maintenance of the ships, helping to make quick verifications with which to make updates. Thus, it is possible for example to carry out during these operations the scan and analysis of the hull, in the search of the detection of dimensional variations that should be repaired or compensated. In the same way, these same tools can be used for verification tasks of piping and any aspect of the internal configuration of the ship's systems, especially if these areas are previously documented in 3D based on previous scans.

- Integration of 3D models in virtual reality and augmented reality applications . The generation of 3D models is an essential requirement to be able to develop the applications of AR and VR technologies in the field of shipbuilding. In this sense, the speed of generation of 3D models from the point clouds captured by a 3D scanner is unparalleled, compared with the time needed to make those models based on conventional metrology and design tools.

Figure 6: 3D scanning of a small boat. Image22 by Marcequintana under Creative Commons licence CC BY-SA 4.0.

Already in 2007, the NSRP (National Shipbuilding Research Program, United States) developed a project in which the verification of two ships23 (Candies Inspection, Maintenance and Repair vessel and SSGN 729 submarine) contemplating the 3D scanning checking of several critical points, resulting in the identification of numerous benefits and the conclusion that already at that time the technology had reached a sufficient degree of maturity to support a digital check process. Since then, the last decade has given rise to a considerable market of 3D scanning systems, with important capacities and certain accessibility from an economic point of view, which has been accompanied by a similar evolution of the 3D data processing software. This means that access to these technologies does not currently encounter significant obstacles, and this is the reason why many organizations offer services in this field, and that specific experiences of incorporation of

22 https://commons.wikimedia.org/wiki/File:Boat_3D_scan.jpg

23 NSRP ASE Ship Check Data Capture Follow-on Project. NRP ASE. 2007. https://www.nsrp.org/wp-content/uploads/2015/09/Deliverable-2005-380-Ship_Check_Final_Report-Electric_Boat.pdf

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technology in shipbuilding companies begin to be visible, such as the Danish OSK-Shiptech24, the Spanish TYM Ganain25, or the Lithuanian Western Baltic Engineering26 ones.

Perhaps the greatest difficulty in implementing these technologies does not come from the technologies themselves (quite accessible, as we have seen), but from the need for them to be implemented through ship-survey projects developed in an efficient and effective time and form.

6.1.4. 3D PrintingAs well-known as Additive Manufacturing (AM, especially in industrial environments), the principle of this technology is the “layer by layer” manufacture, a way of producing elements that, starting from a 3D file/model and dividing it into “slices”, is able to shape an entire element from the progressive manufacture of each one of the layers that form its geometry, using the precise amount of material necessary to make each one of these layers.

Far from being a unique technology, 3D printing is above all a manufacturing concept, which today is reflected in various technologies that vary considerably in characteristics and capabilities, depending on the basic technology used to achieve the layer-by-layer conformation of an element. In this sense, the existing technologies vary from the conformation by sintering of microparticulated material, to the conformation by means of deposition and consolidation (by means of natural cooling, UV curing, etc.) of a layer previously to the deposition of the following one, passing through techniques that achieve a selective shaping of a layer through curing means that can adapt their pattern according to the specific geometry of each layer.

These technologies are beginning to be basic for many designers in the maritime field, who being able to glimpse the virtues described, already implement 3D printing technologies, especially capable to support this stage of the process. This is the case, for example, of the German hydrodynamics research organization Hamburg Ship Model Basin (HSVA)27, which is dedicated to research in the field of hydrodynamics. In 2013 this organization had incorporated an Object Eden350V 3D Machine from Stratasys (Material jetting technology, capable of manufacturing parts in resin material, and with a printing size of around 340x340x200 mm) which led (in 2015) to a reduction of the company´s lead production times by 70%, and reduced its global development costs by 30%.

24 OSK ShipTech introduces 3D laser scanning for ship building. www.geospatialworld.net. 2017.

https://www.geospatialworld.net/news/osk-shiptech-introduces-3d-laser-scanning-ship-building/

25 TYM GANAIN uses the LASER TRACKER OMNITRAC system to align and set its shipbuilding components in the assembling and machining centre. SARIKI Metrología. 2014. http://www.sariki.es/en/news/info/5642/tym-ganain-uses-the-laser-tracker-omnitrac-system-to-align-and-set-its-shipbuilding-components-in-the-assembling-and-machining-centre/

26 Practical 3D Scanning Application for Design and Production. Wester Baltic Engineering. 2018. https://www.linkedin.com/feed/update/urn:li:activity:6442372451539124224

27 3D printing: rising to the challenge in ship design: https://www.ship-technology.com/features/feature3d-printing-rising-to-the-challenge-in-ship-design-4672912/

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Figure 7: Drainage filter made by 3D printing, aimed at draining water from steam flows during operation. Image28 courtesy of the US Navy, Newport News Shipbuilding, Ricky Thompson

The case of HSVA shows that there is not always a need for a sophisticated (and currently not affordable for all budgets) “industrial machine” capable of working with high requirement metals or plastics, but technologies more accessible and “modest”, able to bring important improvements to development stages, critical for the whole success of a new product.

It we turn our view to the manufacturing stage, it is necessary to bear in mind that the size of the part is currently a main limitation for most of existing 3D printing technologies. Although a continuous advance is being experienced and an evolution in this sense is expected, at the moment most advanced (and commercial) 3D printing technologies are not especially suited for the manufacture of large-sized parts (> 1m), with the exception of Direct Energy Deposition technologies (for metals), or some applications for Fused Deposition Modelling technologies (for plastics and fibers). Direct Energy Deposition technologies are undoubtedly the strongest candidates to transfer the capacity of 3D printing to the field of manufacture and repair of large structural parts in the maritime field. This technology results from the union of the material deposition concept with a traditional metallic welding, in such a way that these processes are characterized by having a nozzle capable of depositing and melting metallic material following the layer by layer principle29,30,31. This principle of operation is key to the application of 3D printing to large parts, because by its relative simplicity, it can be implemented through any system with the ability to provide said nozzle with the required mobility, from a robotic arm capable of operating on multiple axes, up to a large Cartesian system. Although these systems can never be for obvious reasons as precise as technologies that work with thin layer thicknesses, this may not be a disadvantage in the field of large parts, where the tolerances are significantly greater, and so to speak, limitations would then be imposed by the required precision, as well as by the dimensions of the systems available to provide mobility to the described nozzle. This technology is in fact being

28 https://navylive.dodlive.mil/files/2018/12/181003-N-N2201-0001.jpg

29 Additive manufacturing ‘revolutionising’ shipbuilding, says OR Laser (Robotics & Automation News): https://roboticsandautomationnews.com/2016/09/16/additive-manufacturing-revolutionising-shipbuilding-says-or-laser/7205

30 Laser cladding technology helps manufacturers ‘go green’ (Industrial Laser Solutions for Manufacturing): https://www.industrial-lasers.com/articles/print/volume-33/issue-2/features/laser-cladding-technology-helps-manufacturers-go-green.html

31 Marine sector sets sail for additive manufacturing (CiM Composites in Manufacturing): https://www.composites-manufacturing.com/marine-sector-sets-sail-additive-manufacturing/

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strongly explored in a special way in the field of repair of parts32,33, in which the achievable savings are evident, in such a way that the development of nozzles and their adaptation to displacement systems allow to foresee a horizon of very clear application for these specific technologies.

Regarding FDM technologies, they are undoubtedly the most accessible AM technologies nowadays, with a wide variability of materials and dimensions, and with a very important scalability, given the relative simplicity of the manufacturing concept. In this sense, and although it is necessary to take into account the limitations shown, its characteristics make it ideal for the manufacture of a multitude of elements of varying size, being in fact a technology that is starting to give birth to commercial machines with interesting capabilities in the scope of large parts; cases like the Dutch company CEAD illustrate it34.

Figure 8: Continuous Fibre Additive Manufacturing (CFAM) machine by Dutch company CEAD. Image used with permission of its original holder

The Netherlands-based additive manufacturing company CEAD is creating an industrial-scale 3D printer that is specifically engineered to help produce parts for ships and other maritime vessels. The Continuous Fibre Additive Manufacturing (CFAM) machine will be able to print engineering plastics and continuous carbon fiber composites, offering a build volume of 4 x 2 x 1.5 meters; equipped with a high-temperature granule extruder, this machine would be capable of printing around 25 kg of material per hour.

In any case, it is interesting to note that by tending the shipbuilding and marine structures sectors to low production volumes (in comparison with sectors that produce consumer goods), one of the main barriers to the implementation of AM, the suitability for high manufacturing volumes, may not be present, and therefore in many cases could lead to operational optimizations that could greatly exceed the costs associated with its implementation. Thus, it is obvious that to give just one

32 THE APPLICATION OF LASER CLADDING TO MECHANICAL COMPONENT REPAIR, RENOVATION AND REGENERATION (DAAAM INTERNATIONAL SCIENTIFIC BOOK 2013):

http://www.daaam.info/Downloads/Pdfs/science_books_pdfs/2013/Sc_Book_2013-032.pdf

33 Is the oil and gas industry ready for additive manufacturing? (EUREKA Magazine): http://www.eurekamagazine.co.uk/design-engineering-features/technology/is-the-oil-and-gas-industry-ready-for-additive-manufacturing-1/160267/

34 CEAD Launches Industrial-Scale 3D Printer Tailored for Shipbuilding (All3DP): https://all3dp.com/cead-launches-industrial-scale-3d-printer-tailored-for-building-ships/

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example, the capabilities of a technology such as Direct Energy Deposition can lead to countless savings by making the repair of parts that usually had to be manufactured again from scratch feasible; in the same way an evolution of fiber extrusion systems can be highly relevant in the field of recreational crafts.

It is interesting to provide just a few examples of how relevant players in shipbuilding industry are facing these technologies. In this sense, the following recent facts are perhaps especially noteworthy:

- Newport News Shipbuilding35 has partnered with 3D Systems to develop metal additive manufacturing technologies. The goal of the joint effort is to revolutionize how the next generation of warships is assembled. As part of the joint development agreement, 3D Systems installed a ProX DMP 320 high-performance metal additive manufacturing system at Newport News Shipbuilding. The state-of-the-art machine is capable of making three-dimensional, marine-based alloy parts for castings or other fabricated parts, such as valves, housings and brackets.

- The new Marine Additive Manufacturing Centre of Excellence at the University of New Brunswick36 in Fredericton is the first of its kind in Canada to combine research, commercialization and workforce development and training. The centre will be the first in Canada to use 3D metal printing as a method for manufacturing certified, custom parts for the marine sector. Its mission is to ensure the adoption of this leading-edge technology in the marine sector in Canada by developing new methods, procedures, and effective training programs.

- Additive manufacturing at Sembcorp Marine37 will focus on the fabrication of large-scale structures for new vessels and component repair, using SIMTech’s Laser Aided Additive Manufacturing (LAAM)38 process.

- Since January 2017, Damen39 is a partner in the RAMLAB, a field lab for Wire Arc Additive Manufacturing (WAAM) in Rotterdam, the Netherlands. Together with a number of partners Damen was working on the development of a 3D printed propeller due for delivery in summer 2017.

35 Metal 3D Printing Accelerates Ship Building (Assembly Marg): https://www.assemblymag.com/articles/94324-metal-3d-printing-accelerates-ship-building

36 New 3D metal printing centre of excellence to revolutionize marine industry manufacturing (University of New Brunswick): https://blogs.unb.ca/newsroom/2017/05/25/new-3d-metal-printing-centre-of-excellence-to-revolutionize-marine-industry-manufacturing/

37 Sembcorp Marine to apply additive manufacturing in shipbuilding revolution (3D Printing Industry): https://3dprintingindustry.com/news/sembcorp-marine-apply-additive-manufacturing-shipbuilding-revolution-124369/

38 LASER AIDED ADDITIVE MANUFACTURING (LAAM). www.fusionworld.sg.

https://www.a-star.edu.sg/Portals/76/Documents/LAAM.pdf

39 Additive Manufacturing (Damen): https://www.damen.com/en/innovation/some-key-projects/additive-manufacturing

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- Hyundai Heavy Industries40 joined the South Korean government’s creative economy

initiative by opening the nation’s 15th creative ‘economy innovation center’ in Ulsan. The Ulsan Center will consist of two branch locations including one branch inside of the University of Ulsan and another in the city’s start-up assistance center building. Both of the centers will help foster South Korean start-ups with a focus on 3D printing and automated medical services industries, however a significant focus will also be placed on boosting the efficiency of the shipbuilding industry through the use of additive manufacturing.

6.2. AutomationThe nature of shipbuilding as a "heavy" industry means that this activity can potentially be particularly benefited by the introduction of automation means (robotized means, fundamentally) that bring optimizations into its production process. As a counterpart, it is widely known that robotization has traditionally been very beneficial especially to those processes of great repetitiveness (since robot programming is a complex aspect of its implementation), and that its application in areas where greater flexibility is demanded is apparently more complex; that is why it is worth considering what is the current state of these technologies and compare it with the current shipbuilding scenario.

The last years are being prolific in news41,42,43,44,45 related to the large-scale introduction of robots in the production processes of some of the largest shipbuilders in the world, being a very representative case Hyundai Heavy Industries46, which in 2018 generated a good number of news regarding its strategy on robotization. More detailed analysis of this type of news allows us to determine in a more concrete way which aspects of the process these organizations intend to automate. Thus, in the specific case of Hyundai, some of the latest advances seem to be confined to the field of welding and painting, through "intelligent" robots47 capable of working no longer repetitively, but adapted to the specific work environment of each case. In a current scenario in

40 World's largest shipbuilder Hyundai Heavy opens up 3D Printing Shipbuilding Innovation Center (3Ders): http://www.3ders.org/articles/20150720-hyundai-heavy-industries-opens-up-3d-printing-shipbuilding-innovatinon-center.html

41The digital shipyard: robotics in shipbuilding. www.ship-technology.com. 2013 https://www.ship-technology.com/features/feature-the-digital-shipyard-robotics-shipbuilding/

42 Watch Out, the Robot Shipbuilders Are Coming. www.bloomberg.com. 2018. https://www.bloomberg.com/news/articles/2018-04-15/robots-in-the-dockyards-shipbuilders-automate-to-reduce-costs

43 Welding USA: is the American shipbuilding industry ready to embrace new robotic technology? www.ship-technology.com. 2017. https://www.ship-technology.com/features/featurewelding-usa-is-the-american-shipbuilding-industry-ready-to-embrace-new-robotic-technology-5806100/

44 Shipbuilders set to increase use of robotics and automation technologies. https://roboticsandautomationnews.com. 2018. https://roboticsandautomationnews.com/2018/04/18/shipbuilders-set-to-increase-use-of-robotics-and-automation-technologies/16923/

45 The Rise of the Shipbuilding Robots. https://industryeurope.com. 2018. https://industryeurope.com/the-rise-of-the-shipbuilding-robots/

46 Hyundai Heavy to use robots in ship construction. https://safety4sea.com 2018. https://safety4sea.com/hyundai-heavy-to-use-robots-in-ship-construction/

47 Hyundai Heavy reports breakthrough in shipbuilding robotics. www.marinelig.com. 2018

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which the personalization of the product is a fundamental requirement, the repetitiveness in any type of operation, and of course in tasks such as those described, does not seem to be frequent, so it is the development of this "intelligence" associated with robotic systems where perhaps special attention should be paid. In order to explore this concept, let us analyse in a general way a robotic welding operation:

- As in any manufacturing operation carried out in a traditional way by robotic means, the process demands a work of programming, that defines which are the positions and/or trajectories that the robot has to reproduce to perform the required operation (in this case a welding operation). If we also place our focus on welding processes of large parts, the welding processes is not punctual, being required to define lines or welding trajectories, which ensure the correct union of the parts.

- The methods for the definition of welding trajectories can be varied, but in general they require a previous phase of determination of all the points that will make up the trajectory of the robot along the length of the weld. So, to give a simple example (very simple to promote the understanding of this process), it is possible to depict the case of a metal frame on which an additional plate should be welded:

Figure 9: Simple example of flat parts welding. Own creation

- The determination of these points requires a considerable time, both for their definition and for the development of the subsequent programming that will allow the robot to carry out the welding.

- The above is feasible when the number of parts to be welded is large and/or a repetitiveness of said welding operation is foreseen, but when that welding is going to be unique or not sufficiently repetitive, these tasks generate relevant costs, and non automated means tend to be more cost efficient.

https://www.marinelog.com/index.php?option=com_k2&view=item&id=28519:hyundai-heavy-reports-breakthrough-in-shipbuilding-robotics&Itemid=257

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This example48 (Fundación Prodintec, internal project for the application of technologies of artificial vision to the welding of big flat parts) basically illustrates the main reason why the introduction of robots for welding operations tend to be not economically viable in activities of certain flexibility, since the possible improvements in terms of quality are offset by the cost of the investment and the operating cost of the tasks necessary for the previous programming of the robot.

However, in recent years this situation has begun to change, thanks to the incorporation of new concepts and technologies in the field of robotics, and specially thanks to the recent advances in sensors and fields such as artificial vision, that are allowing to evolve robotics towards a concept of intelligent, collaborative and flexible automation.

In a simple way, and applied to the industrial environment, artificial vision would be the process of automatically acquiring images and it subsequent analysis, with the purpose of characterizing an object, element, operation, process, activity, etc., through said process, and extract the necessary information that allows carrying out a specific task in relation to them. Artificial vision has many applications, such as the measurement of parts without contact, rel time quality control, the recognition of people, the recognition and scanning of objects, etc., as well as those arising from their integration with other technologies. In this line (following the example used in this section) it is possible to develop capable systems, that for example:

- Prior to carrying out the welding work, recognize the parts and surfaces to be welded, scanning them to define an accurate 3D model of the elements to be welded.

- Using algorithms developed for this purpose, compare the extracted 3D image with the nominal values (2D planes - original 3D models) and establish and adjust the points that determine the welding trajectory. An operator could review and make adjustments later, but there would have been significant savings in the time needed to determine the spatial coordinates of the different points of the welding trajectory.

- As a result of the defined welding trajectory, the robotic welding process can be carried out, with a considerable saving in the time required to perform such an operation without this capability.

This type of applications are feasible with current technology (there is a wide range of cameras and vision sensors in the market, with different capacities and accuracies, as well as software and hardware tools with the capacity to develop this type of applications), so currently, the implementation of automation technologies in areas where flexibility is demanded is more a matter of delimitation of the problem to be solved, than of the technology itself. This is the true essence of today's robotics, which endowed with "intelligence" and collaborative capacity thanks to the recent development of complementary technologies, has today a greater ability for providing improvements to different environments and situations than in previous times. That is why in the near future the robots for specific operations will integrate a series of systems (hardware and software) that will increase their versatility, and not only shipbuilders of bigger size, but smaller

48 Fundación Prodintec: Internal project of application of technologies of artificial vision to the welding of big flat parts. 2015

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organizations can benefit from them, at the same time that for the latter it is also possible to consider the development of specific innovations to meet their own requirements.

6.3. Simulation and Immersion TechnologiesVirtual and augmented reality are two concepts from which the "virtualization" of an activity is addressed, either through the creation of a complete virtual environment where a user can operate (virtual reality), either through the superposition of information and complementary images on the user's field of vision (augmented reality). Both technologies are manifested in a similar way (specific softwares, helmets, glasses and other accessories to interact in virtual or augmented environments), although they have differentiated potential applications:

- Virtual reality focus its potential applications in simulation and training. The existence of a totally virtual environment makes it possible to replicate a real environment and simulate the activity that would be developed in that environment, so that its application in aspects where actions are demanded in the absence of the real environment or training operations are the ones which in principle are more susceptible to its application.

- The augmented reality does not seek to replicate and virtualize an environment and experience, but to complement the visible information (by the human eye) with additional real-time information, capable of optimizing and facilitating an operation. Thus, verification and maintenance activities are some of the activities with greater projection of these technologies, as their ability to be benefited from additional information (data, references, models for comparison, etc.) through a simple overlay of information over the real image (which can be achieved not only with specific media such as AR glasses, but with any mobile device equipped with cameras and softwares of sufficient capacity) is very important.

Figure 10: Recreation of the application of virtual reality in the simulation of a maintenance environment on a ship. Image49 courtesy of the United States Navy. Lt. Clay Greunke and Dawn Stankus.

These technologies are beginning to find specific applications in the field of shipbuilding (articles such as "A Review on Industrial Augmented Reality Systems for the Industry 4.0 Shipyard50" or

49 https://www.doncio.navy.mil/FileHandler.ashx?id=10340

50 A Review on Industrial Augmented Reality Systems for the Industry 4.0 Shipyard. Paula Fraga-Lamas, Tiago M. Fernández-Caramés, Óscar Blanco-Novoa, Miguel A. Vilar-Montesinos. Uniersidade a Coruña, Navantia. 2018.

https://ieeexplore.ieee.org/document/8298525

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"Virtual Reality in a shipbuilding environment51" are good examples), and organizations such as Navantia, BAE Systems, IndexAR or Newport News Shipbuilding are developing and testing solutions based on these technologies, although its use cannot yet be considered widespread. We show some of the representative application cases below:

- Danish ship design firm Knud E Hansen (KEH) has developed a VR tool called ShipSpace52, a 3D rendering engine that in their own words “allows engineers, designers and owners to walk on board their new vessels from preliminary design stages all the way through construction”. They have been able to develop a 3D engine for shipbuilding, making possible for a shipbuilder to correlate and incorporate its 3D models into complete 3D environments that allow to replicate and “walk” through a digital version of the ship.

- German Cruise shipbuilder Meyer Werft53 has enabled a VR room where engineers can analyse structural elements before manufacturing them, during the planning phase, including complete steels models, pipelines, shafts and cables, equipment, etc.

- Military contractor BAE systems uses virtual reality for the analysis and improvement of the 3D cads of the ships that they design for the navy, being able to make appreciations of the general design, scale, detail, etc., hardly comparable with a conventional display of the information. Thus, thanks to a VR visualization they can evaluate aspects such as the security of the environments, actions to take in front of risks and unforeseen events, etc.

- Dutch Damen Shipyards54, is as well testing VR and AR technologies. In the latter case, they are experimenting with applications in the maintenance field, for example testing augmented vision systems and applications to tell an operator that a part is close to the end of its planned lifespan and has to be substituted, as well as informing about the availability of a replacement part.

- A similar use of AR has been tested by Newport News Shipbuilding55 one of the US Navy main ship providers, that uses AR for seven applications (work instruction, cable routing, inspection, workflow management, training and operations), thanks to tablets loaded with a specific AR software that provides on screen information for helping operators repairing or performing cable installations.

51Virtual Reality in a shipbuilding environment. RodrigoPérez Fernández, VerónicaAlonso. SENER Ingeniería y Sistemas. 2015. https://www.sciencedirect.com/science/article/pii/S0965997814001872

52 ShipSpace: Groundbreaking Virtual Reality design system. Knud E Hansen. https://www.knudehansen.com/shipspace/

53 Improving the Quality by Virtual Reality. Meyer Werft.

https://www.meyerwerft.de/en/meyerwerft_de/werft/produktionstechnik/virtual_reality/virtual_reality.jsp

54 Damen Magazine. 2018. https://magazine.damen.com/innovation/virtual-and-augmented-reality-in-shipbuilding/

55 Brian Bare Builds Ships with Augmented Reality. CA Technologies. 2017. https://www.ca.com/us/modern-software-factory/content/brian-bare-builds-ships-with-ar.html

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- Navantia (Spain). A specific activity on “A Fog Computing and Cloudlet Based Augmented

Reality System for the Industry 4.0 Shipyard56” was carried out in recent years under the framework of its Shipyard 4.0 initiative. Under this activity they focused on the development of a low-latency system for the exchange of information on AR environments that was tested on different applications, as remote guiding for maintenance operators or 3D images projection.

Based on its characteristics, VR and AR technologies are therefore complementary in the realization of various activities within the field of shipbuilding, being really its applicability greater depending on the degree of use by the shipbuilder of other digital technologies. In this sense, the implementation of systems that lead to a standardization of the use and agile transmission of digital information will allow its implementation in augmented and virtual reality applications.

6.4. ICT and Digitalization.In relation to ICT, there is a good number of terms that are becoming common in any industrial field: digital industry, industry 4.0, Big Data, Internet of Things, Connected Industry, etc. Although all these concepts present their own "personality", all of them arise in the framework of the implementation of technologies that result in a digitalization of productive activity. In this sense, all the technologies and developments framed within the ICT concept are applicable to the field of shipbuilding, but bearing in mind that the said digitalization is a mean, but not a goal. Thus, and in relation to the applications described above:

- Digital manufacturing technologies . Logically, information and communication technologies form the basis of all systems, processes and activities in the field of digital manufacturing, being the basis not only for the existence of systems and computer programs capable of managing the information, but enabling the creation of standards, communication protocols between applications, integration of information in intranets and in the “cloud”, etc. In this way, the increase in the power of computing computer systems and the development of advanced algorithms has allowed the irruption of simulation technology and 3D scanning, as well as the application of algorithms for the optimized and design of lightened structural elements, and the progressive evolution of 3D printing technologies towards maturity.

- Automation . Advances in ICT are enabling the development of intelligent, collaborative and flexible robotization concepts, unthinkable in the classical paradigm of machines in which each one of its actions must be programmed in a detailed manner. Thus, the development of complex decision systems or, more commonly, "artificial intelligence", is a key aspect of this automation57.

- Simulation and Immersion technologies . The considerable increase in the computing power of the systems, the development of visualization software for virtual environments, and the

56 A Fog Computing and Cloudlet Based Augmented Reality System for the Industry 4.0 Shipyard. Tiago M. Fernández-Caramés, Paula Fraga-Lama, Manuel Suárez-Albela,, Miguel Vilar-Montesino. Universidades A Coruña, Navantia. https://ruc.udc.es/dspace/bitstream/handle/2183/21097/Tiago_M._Fern%C3%A1ndez-Caram%C3%A9s_2018_A_Fog_Computing_and_Cloudlet_Based_Augmented_Reality_System.pdf?sequence=3&isAllowed=y

57 South Korea Invests in AI for Shipyards. The Maritime Executive. 2018. https://www.maritime-executive.com/article/south-korea-invests-in-ai-for-shipyards

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parallel development of the systems of creation and standardized management of 3D files is allowing to introduce in the development processes a new dimension, in which the recreation of a product can be made "almost palpable", leading to new interactions during the process.

The above are just some examples of how ICT is supporting development in the field of shipbuilding, being an extraordinary driver for the integration of new technologies.

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7. LOOKING TO PATENTS TO MEASURE ADVANCED MANUFACTURING RELEVANCE

As a brief introduction to the methodology used to elaborate this section, the authors have made use of the Derwent Innovation58 tool as a main patent database, which has allowed to carry out a series of preliminary studies to give rise to the data shown. Aiming at results and analyses done to be reproducible by any reader, the use of the previous tool has been complemented by the use of the free search tool available at Lens.org59, which allows free searches and a simple analysis and filtering of patent information.

Being advanced manufacturing a concept under which a great number of technologies are included, and being at the same time the shipbuilding a broad industrial activity, the realization of a detailed analysis of how applications as those previously described are represented in the state of the art of patents is highly complex, since any related search will easily yield tens of thousands of results. However, it is possible to carry out a more global analysis, based on the international classification of patents, which identifies a family of patents called "B63B: SHIPS OR OTHER WATERBORNE VESSELS; EQUIPMENT FOR SHIPPING". This family is subdivided in turn into dozens of second and third level subfamilies, in such a way that the activities involved in shipbuilding would be fundamentally encompassed under the previous code.

Figure 11: B63B (Ships or other waterborne vessels; equipment for shipping) patent family (according to International Patent Classification60)

58 https://www.derwentinnovation.com tool (proprietary software) created by Clarivate Analytcis, that gives access to a curated database of patents, allowing complete searches and processing of data, used by professionals in the field of patents.

59 https://www.lens.org/

60 https://www.wipo.int/classifications/ipc/en/

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In order to perform a minimum filtering to assess how in recent years the protecting activity regarding shipbuilding has evolved, it is possible to carry out a search that also filters the results based on the existence in the abstract of the different patent documents of the word "manufacturing", and also restrict the results to the period 2010 - 2018. Analysing the data under these conditions, more than 3.800 patents are obtained as result, being possible to make the following evaluations:

- Temporal evolution of the number of published patents . The following data shows how the production of patents in the field of manufacturing related to shipbuilding has consistently doubled (even tripled in 2018) during this decade, which indicates that, far from stagnating, has increased its pace considerably.

YearPublished

PatentsAnual

Growth2010 244 44,38%2011 245 0,41%2012 409 66,94%2013 466 13,94%2014 528 13,30%2015 425 -19,51%2016 507 19,29%2017 419 -17,36%2018 600 43,20%

0

100

200

300

400

500

600

700

2010 2011 2012 2013 2014 2015 2016 2017 2018

Published Patents "manufacturing" (abstract) +IPC Code B63B 2010 - 2018

Figure 12: Temporal evolution of the number of published patents under IPC code B63B + “manufacturing” search (abstract) for the period 2010-2018. Data Source: Lens.org. Tables and charts: own creation

- Prominent patent families . The graph below shows as prominent patent families the following ones:

o Methods of designing, building, maintaining, converting, refitting, repairing, or determining properties of vessels.

o Methods of building hulls.o Floating buildings, stores, drilling platforms, or workshops, e.g. carrying water-oil

separating deviceso Load-accommodating arrangements, e.g. stowing or trimming; Vessels

characterised therebyo Vessels or like floating structures adapted for special purposes.

All most prominent codes are especially indicative that an important industrial protection activity is taking place in every aspect related to the manufacture of floating structures, which together with the previous data points towards the appreciation that the increase in inventive activity has also been very palpable in areas directly related to the construction of vessels.

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IPC Code Description

Published Patents

B63B9/00Methods of designing, building, maintaining, converting, refitting, repairing, or determining

526

B63B9/06 Methods of building hulls 525

B63B35/44Floating buildings, stores, drilling platforms, or workshops, e.g. carrying water-oil separating

394

B63B25/16Load-accommodating arrangements, e.g. stowing or trimming; Vessels characterised

331

B63B35/00Vessels or like floating structures adapted for special purposes

169

B65D90/06Component parts, details or accessories for large containers. Coverings, e.g. for insulating

133

B63B17/00Vessels parts, details, or accessories, not otherwise provided for

132

B63B22/00 Buoys 108

F17C1/12 Pressure vessels, e.g. gas cylinder, gas tank, replaceable cartridge, with provision for thermal

97

B63B13/00Conduits for emptying or ballasting; Self-bailing equipment; Scuppers

95 0 100 200 300 400 500 600

B63B13/00

F17C1/12

B63B22/00

B63B17/00

B65D90/06

B63B35/00

B63B25/16

B63B35/44

B63B9/06

B63B9/00

No. Patents "manufacturing" (abstract) + IPC Code B63B 2010 - 2018 per subcodes

Figure 13: Patent main sub-codes count under IPC code B63B + “manufacturing” search (abstract), for the period 2010-2018. Data Source: Lens.org. Tables and charts: own creation

- Most active patenting countries . The distribution shown by the following chart leaves no room for doubt: China and Korea accumulate practically more than 80% of the industrial protection activity in the field of manufacturing related to shipbuildin throughout this decade.

CountryPublished

Patents%

China 2.002 52%Korea 1.103 29%USA 156 4%

Japan 166 4%Europe 58 2%

World Patents 136 4%Russia 66 2%

Australia 37 1%Other Countries 119 3%

52%

29%

4%

4%

1%4%

2% 1%3%

Published Patents "manufacturing" (abstract) + IPC Code B63B 2010 - 2018 by country

China

Korea

USA

Japan

Europe

World Patents

Russia

Australia

Other Countries

Figure 14: Most active patenting countries under IPC code B63B + “manufacturing” search (abstract), for the period 2010-2018. Data Source: Lens.org. Tables and charts: own creation

- Main applicants . A simple analysis of the main patent applicants is consistent with the data we have just shown, and is that most prominent names belong to Korean shipbuilders: Daewoo, Samsung, and Hyundai. These three organizations gather more than 15% of the total patent production, which although does not suppose a majority of the patent production is clearly indicative that these are very prominent actors when it comes to protect and commercially exploit manufacturing innovations for shipbuilding.

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OrganizationPublished

Patents%

Daewoo Shipbuilding & Marine 213 5,5%Samsung Heavy Ind 192 5,0%Hyundai Heavy Ind Co Ltd 179 4,7%Weihai Zhongfu xigang Ship Co 47 1,2%Mitshubishi Heavy Ind Ltd 38 1,0%Hudong Zhonghua Shipbuilding 34 0,9%Guangzhou Shipyard Int Co Ltd 33 0,9%CSSC Huangpu Wenchong 28 0,7%STX Offshore & Shipbuilding Co 27 0,7%Chengxi Shipyard Co Ltd 27 0,7% 0 50 100 150 200 250

STX Offshore & Shipbuilding Co

Chengxi Shipyard Co Ltd

CSSC Huangpu Wenchong Shipbuilding Co Ltd

Guangzhou Shipyard Int Co Ltd

Hudong Zhonghua Shipbuilding

Mitshubishi Heavy Ind Ltd

Weihai Zhongfu xigang Ship Co

Hyundai Heavy Ind Co Ltd

Samsung Heavy Ind

Daewoo Shipbuilding & Marine

No. Patents manufacturing" (abstract) + IPC Code B63B 2010 - 2018 per applicant

Figure 15: Most active patenting organizations under IPC code B63B + “manufacturing” search (abstract), for the period 2010-2018. Data Source: Lens.org. Tables and charts: own creation

Far from constituting an in-depth analysis, the data shown are nevertheless good indications that:

- The increase in industrial protection activity in the present decade in the field of shipbuilding can be derived from an increase in the pace of innovation and technological change in the sector.

- The most frequently addressed topics are 100% alignible with the shipbuilding activity.- China and Korea are carrying out a protection activity substantially ahead of the United

States, Japan and Europe.

In addition to the analysis carried out, a series of references to some representative patents on advanced manufacturing for shipbuilding have been included as an annex to this document.

8. CONCLUSIONSThis document has been intended to act as a brief summary of some of the main potential applications of some of the most important technologies included under the advanced manufacturing KET, developing an analysis that going from the general to the particular has intended to be illustrative of the reasons why this KET is highly relevant to the shipbuilding business and is key to its improvement.

The work reflected in this document leads to a summary of the most important facts:

- Behind the concept of advanced manufacturing there is a wide range of technologies capable of offering new possibilities for the improvement of manufacturing processes in the field of shipbuilding. The range of technologies is very broad, although nowadays we can identify a number of major technologies, with the capacity to cover the entire shipbuilding process: 3D design and management tools, manufacturing process simulation technologies, scanning and 3D printing, automation, virtual and augmented reality and the necessary complement of information and communication technologies.

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- Each of the above technologies is implementable in an isolated or integrated manner,

based on the needs of each organization. In this sense, technology is never the final goal, but the means through which to achieve operational benefits, and any implementation must start from a clear definition of needs and improvement goals, from which to evaluate the possible role of the technology available.

- As a general assessment of the technologies exposed in the different stages of the product's life cycle:

o 3D design and management technologies offer clear benefits in terms of error reduction, streamlining of change and reuse of information, although traditional 2D design systems are still highly efficient in the initial stages of development, which hinders the implementation of 3D tools in these stages, and therefore in the process as a whole. These tools are evolving and it is worth making a close follow-up of them, so that each organization can determine from which point the migration to the "total" 3D concept allows them to respond in all the stages of a project in an agile and effective way.

Regarding the simulation technologies of manufacturing processes in the field of shipbuilding, there are specific application cases that are of great interest when evaluating their potential in terms of flexible planning of the activity, although they require a considerable level of information and digitalization.

o In the field of manufacturing, additive manufacturing and advances in robotization and automation can provide capacities not yet foreseen. Although by its nature, the 3D printing of large metallic structural elements is not foreseeable in the short or medium term, the existing and developing technologies seem to be potentially capable for the manufacture of vessels based on fibers and other plastic materials; In any of the cases, the possibilities of these technologies in supporting to the design and development of elements and small equipment is beyond doubt.

In the field of automation, the current concepts of robotics (integrated with different technologies that provide flexibility and collaborative capacity) are evolving towards the possibility that robots can be effective tools not only in repetitive manufacturing, but in environments that demand greater flexibility.

o Virtual and augmented reality technologies are beginning to be implemented in the field of shipbuilding, with various possibilities ranging from the mere virtual recreation of environments and spaces, to the use of this technology as a tool for design (visualization and design correction), passing through its potential applications in fields such as maintenance.

o Information and communication technologies are a “must have” complement, not only to create fully digital environments where it is possible to transmit and share information no matter where, who and how, but to support the maximum exploitation

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of previous technologies, as well as to enhance the benefits of integration among all of them.

- A summary analysis of the industrial protection activity in the field of shipbuilding is an indication that the previous technologies may be causing a significant impact on the sector, by virtue of how the inventive activity has more than doubled in the present decade, and how the most active agents (China and Korea) are precisely those that have emerged in recent years as main powers within the sector.

As a final point, this document has been intended to provide a small “grain of sand” in the work of transferring organizations operating in maritime sectors, and more specifically that of shipbuilding, how advanced manufacturing is impacting the sector, through examples and useful references. We hope that this work has been to your liking, and that we have fulfilled our task.

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9. ANNEX: Representative Advanced Manufacturing for Shipbuilding PatentsSome representative recent patents on advanced manufacturing in shipbuilding are shown below (free patent databases like Espacenet61 can be used to consult them in more detail):

- Digitalization of design, product management and manufacturing of a ship:

o Zhu Weipeng, Zeng Xianhua. “Digital Information Integration Method of Lng (liquefied Natural Gas) Ship”. CN 103693163 A.

o Kawakita Chiharu, Kitamura Toru, Onaka Shigeki, Gokouchi Yuichi, Araki Shinichi. “Ship Design Support System”. JP 2012076680 A.

- 3D printing implementation:

o Carlsten Curtis B, Murrow Jonathan, Item Erik F. “Method for Manufacturing Polymer-metal Composite Structural Component”. US 9920429 B2.

o Fleischer Corey A, Ascari Matthew B, Gaigler Randy L, Poppek Michael W, Waicukauski James A. “Additive Manufacturing Of Pipes”. WO 2016/077119 A1.

o Cox David. “Buoyancy Module and Method of Forming”. WO 2016/086268 A1.o Trockel Dale Forrest. “Water Sports Boards Having Pressurizable / Inflatable Baffle

Chamber Structures Therein, Which Are Manufacturable By Way Of 3d Printing”. US 9694540 B2.

o An Meiqi, Guo Yu, Yu Feng. “Remote Control Racing Boat And Manufacturing Method Thereof”. CN 107757837 A.

- Simulation technologies implementation:

o “Radar Mast Production Method For A Ship”. KR 101197381 B1.o Park Jin Hyung, Rhee Si Youl, Kwon Ki Youn, Erkan Gunpinar. “Apparatus And

Method For Simulating Manufacture Of Main Flate”. KR 20120051438 A.o Liu Yuanbin. “Test Method For Type Selection Of Anchorage Device Mooring

Mode”. CN 107933825 A.

- Automation implementation:

o Du Zhenhuang, Wang Huaming. “Automatic De-rusting Machine For Hull Outer Plate”. CN 104816764 A.

o Yao Qiguo, Wang Huaming. “Large Hull Surface Absorption Construction Platform”. CN 104816763 A.

o Zhao Yao, Yuan Hua, Hu Changcheng, Yan Jun. “Automatic Marking Device For Ship Hull Section Outer Plate”. CN 103434609 A.

o He Zifen, Wu Qike, Zhang Yinhui, Tang Haiyan. “Overwater Duckweed Removing Robot”. CN 107386233 A.

61 https://worldwide.espacenet.com/

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- Virtual and augmented realty implementation:

o Lee Jeong Youl, Kil Woosung, Son Myeong Jo. “A Virtual Reality-based Management Method Combining Drone Inspection Information”. KR 101845796 B1.

o Kim Dae Hee, Kim Hyun Been, Kim Won Ouk. “Apparatus And Method For Virtual Reality Training Simulation”. KR 20180064026 A.

o Park Se Kil, Oh Jae Yong, Kim Hye Jin. “System And Method For Automatic Tracking Of Marine Objects”. KR 20180065411 A.

o Bang Kyoung Woon, Kim Hyeong Cheol, Choi Woo Young, Lee Chan Young, Kim Jae Kwan, Oh Eun Sung. “Visualization System Of Battleground Situation And Method Thereof”. KR 20160081139 A.

o Roh Myung Il, Ham Seung Ho. “Integrated Simulation Apparatus Based on Physics Based Analysis Realistic Visualization and Hardware Simulator for Shipbuilding Production and Offshore Installation and the Method Thereof”. KR 101723678 B1.

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