Production (Detail) Design - simplifying & streamlining production
The seminal component of a valuable production design package is an accurate and comprehensive production model, developed to the appropriate level of detail as defined by the needs of a particular client. Early integration of as many components as possible into a comprehensive model can identify interface issues, allowing for efficient and cost-effective design solutions. The Gibbs & Cox production design process includes integration of a 3D CAD product model of the vessel based on classed and approved functional drawings, vendor drawings, and the shipyard’s build strategy in a configuration optimized for vessel construction. Production drawings and information are extracted from the 3D product model to support complete construction of the vessel in a sequence and format best aligning with the build processes and work centers at the shipyard. This includes 3D and 2D drawings and CNC data for structural assembly, piping, mechanical, hull outfitting, electrical, and HVAC.
Gibbs & Cox uses various 3D CAD/CAM software tools including ShipConstructor and Intergraph. We apply over 30 years of CAD experience and numerous processes to the execution of modeling, drawing extraction, design control, and configuration management under an ISO 9001 quality management system. Our processes are scalable and customizable to shipyard’s capabilities, preferences, vessel complexity, and schedule. During production design, we follow design for production (DFP) and design for maintenance (DFM) approaches and implement proven methods to improve construction efficiency for the shipyard and reduce lifecycle operating costs.
Components of a fully-integrated production design package include:
- Construction design details for metal, composite & wooden structures
- Fabrication & assembly packages and reports
- Part profile data & CNC part files
- Packaged deliverables
- Assembly drawings & construction aids
- Bill of material (BOM) & loft data
Hull, Deck, and Superstructure Construction Details Design
Gibbs & Cox uses parametric modeling software to develop fully-faired, three-dimensional models of the complex geometries typical of marine vessels. In addition to a vessel’s hull, deck(s), and superstructure, models can include features such as interior surfaces, outfitting equipment, machinery components, vessel systems, and their associated penetrations. Drawings integrating ship systems, penetrations, and structures are developed. Total hull and superstructure outfitting & production details can be incorporated. Building standards, weld schedules, system descriptions, classification society documentation, and shipboard drawings can be included.
Fabrication & Assembly Packages & Reports
The production model and comprehensive construction information are fully developed and incorporated into a single package providing all information needed to purchase raw material, manufacture parts, fabricate, assemble, and erect the entire vessel from stem-to-stern. Several types of reports can be generated from the production model, virtually in seconds, to provide information including part and assembly weights & centers, interference checks, material ordering schedules and lists, and other supplemental builder-specific information sets.
Part Profile Data & CNC Part Files
Ready-to-cut CNC files are developed to suit specific client requirements. Three-dimensional shaping information and fabrication/assembly instruction packages are developed to facilitate specific construction techniques as required by client practices. For metal vessels, cut-plate parts ultimately become pieces of the actual hull, deck, or house structure. For wooden vessels, cut parts are typically assembled into jigs (either re-usable or disposable) over which cold-molded surfaces can be laminated. For composite vessels, computer surface models are used to develop the tooling paths for robotic milling of 3D tooling parts (plugs and molds).
As the production model is developed, accurate dimensional information is integrated, including material thicknesses and dimensional effects of surface finishes and treatments, as well as client and manufacturer tolerance requirements. All parts are assigned numbers and can include markings, registration lines, and reference information. All parts are inventoried, with their numbers and attributes, as individual components of an integral parametric database, ensuring accuracy, control, and documentation of the entire model. As the development of the model evolves, the inherent adaptability of the parametric modeling allows all modifications to be reliably integrated into the complete package in real time.
Assembly Drawings & Construction Aids
The number and complexity of individual assemblies varies from builder-to-builder, based on specific requirements. Individual parts are grouped into assemblies that can be as large as an entire vessel or as small as a single stiffened panel. To facilitate modular construction and modern productivity techniques, a complete assembly hierarchy is created during the modeling process, and is used to produce the appropriate assembly drawings relative to each assembly.
To ensure accuracy of fabrication, assembly, and erection processes, several types of construction aids can be provided, including pin- or plate-jig creation, inside- or outside-template creation, sight, reference, or registration markings, and any number of critical check-dimensions. The final quality-control tools included with the production information package is customizable to suit individual builder practices and requirements.
Bill of Material (BOM) & Loft Data
Industry-standardized bills of material are provided, documenting all parts and their associated attributes, and can be included as a part of an assembly drawing or as stand-alone reports. Limitless customization can be incorporated into BOM reports as required by the builder, and reports can be provided at any stage of the design/build process to support management, procurement, engineering, and build team activities.
All loft data required to produce, manufacture, and fabricate structural parts and piping systems are output from the production model. Output is delivered in the form of drawings, reports, and tabulated data files for direct input into CNC machines. In addition to flat-plate and pipe dimensional information, part curvature and bend geometries (including simple bent/flanged profile information and three-dimensional simple and compound curvature descriptions) are provided.