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Productivity Challenges in Shipbuilding Industry

The long product development cycles that occur due to the current workflow has to lead the shipbuilding industry to incur huge losses in both time and cost. The lack of any technology adaptation to improve the design review process has in a way crippled this industry, the closure of some of the world’s oldest shipyards is a compelling reason for ushering in the much-needed change in the process. While CAD has helped immensely in improving the initial design conceptualization, it has close to no benefit while used as a review tool simply because of the lack of real scale visualization. This leads to the continued use of large scale physical prototyping, the accuracy of which is assumptive and the repeated need for these in the process is the major reason for the time and cost escalations. Furthermore, these prototypes served the purpose of allowing validators an overview review of the models only, completely failing to address any ergonomics related manufacturability, serviceability and usability challenges that usually get identified in the manufacturing stage (once again leading to escalations in time and cost). 

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Digital Transformation case studies for Shipbuilding Industry

Introduction of Virtual Prototyping

With the onset of immersive technologies in product development, the concept of Virtual Prototyping was introduced to counter the challenges the industry faced due to physical prototyping. With this shipyards now had access to a technology that allowed 1:1 scale visualization of their models without the need for repetitive physical prototyping. Furthermore, the technology also came with a host of digital mockup tools that made the initial design reviews much more accurate, thereby reducing the losses incurred by a great margin. However, a challenge remained, the need for data conversion before the model could be brought into the virtual environment. 

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Exxar CAD converts any desktop 3D CAD into a collaborative extended reality experience in real-time.

Exxar CAD to VR

With Exxar and its unique ‘no export-no import’ CAD to VR technology, users can instantly transform the native 3D CAD data of the ship compartments from the CAD desktop application, into a 1:1 scale, interactive prototype, with just a click of a button. Once the data gets into the virtual environment, the amazing in VR UX allows natural interaction and collaboration in the immersive environment for early validation of various possibilities in the manufacturing stages. Factor in its Build functionality for interaction focused assessments and the Human module for ergonomics assessments, we can safely say that Exxar is truly revolutionizing the design to development standards in the shipbuilding industry, eliminating the time and cost escalations in the process.

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Design Review & Approval

In the current process designs, prototypes, sketches are created using 3D tools. They are collaborated on and showcased to external stakeholders using print outs, charts, physical mockups. This complicates the design review process and also causes project milestone delays. With Exxar CAD to VR users can now have access to 3D CAD design data to VR in 1 click,

  • 1:1 scale model visualization
  • Review with appropriate background environments
  • Collaborative design review
  • Use digital mockup tools
  • Record design errors 
  • Give feedback during the review
  • Instant change assessment in VR

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Before After shipbuilding design review
shipbuilding design review

Manufacturability & Serviceability

Before After shipbuilding manufacturing
shipbuilding manufacturing

Most shipyards don’t have access to technologies to assess manufacturability and serviceability. Design and production planning faults like visibility, reachability, tool interactions all for dense assemblies like ship compartments results in expensive rework. This also delays production and leads to huge cost escalations,

  • The virtual layout of the entire ship 
  • Validate operator interactions in the design stage
  • Validate the visibility of operators
  • Assess blind spots in the model
  • Assess accurate assembly sequencing
  • Negate reachability & accessibility faults
  • Give feedback to the design team
  • Finalize changes in the design stage

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Ergonomics

Ergonomics validation of postural stress and strain for operators performing inspection and general operations both while manufacturing and live operations is currently a highly assumptive process relying heavily on desktop applications leading to inaccurate conclusions. The manufacturing delays are proof that an upgraded system needs to be introduced to counter the challenges

  • Virtual Layout of the whole ship
  • Place Virtual human at critical points
  • ‘Possess’ virtual human
  • Perform human tasks, actions
  • Identify postural stress in run time
  • Validate possibility with interpenetration
  • Check tooling viability
  • Optimize ship layout

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Before After Ergonomics Shipbuildingshipbuilding ergonomics
Ergonomics Shipbuilding

Product Showcase

Before After shipbuildingShip design showcase
shipbuilding

Showcase currently relies heavily on physical models with ‘marked’ layout changes or videos or charts, which are either very expensive to set up or lack the immersive edge that keeps the audience engaged. Even in the best of cases, certain change requests increase the cost of introducing further changes

  • Multi-users + 3D CAD in VR meeting
  • Immerse the audience in 1:1 scale
  • Set context with background environments
  • Collaborate with all stakeholders if required
  • Note customer feedback during the showcase
  • Real-time change request in CAD
  • Live showcase of the modified design

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Training

The chance for accidents during operations has always been a concern in the shipbuilding industry. Training currently is in non-engaging classrooms or computer-based training. On the job training, on the other hand, is very expensive, further increasing risks at the job site

  • Final model data from CAD to VR
  • Familiarise operator in 1:1 scale with a model
  • Improve layout understanding
  • Perform operator tasks in VR

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Before After shipbuildingtraining ship
shipbuilding

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FAQ (Frequent Asked Questions)

Exxar supports all 3D CAD applications including AVEVA review, AVEVA outfitting, CADMATIC and popular review applications like Navisworks.

Regardless of the size of the model, Exxar guarantees to be faster than any other product in the market

Exxar supports various hardware devices from OEM’s like HTC, Oculus, ART, Manus, Barco and the like

Yes, It is possible. Exxar has a very dynamic walkthrough/flythrough feature which allows users to seamlessly navigate around the model

You can record the whole screen and take snapshots as well which you can send to the Designers. Through annotations, reviewers can also share his/her feedback in the form of comments with designers.

Yes, As long as the metadata is defined on the CAD model itself, you will be able to access it in Exxar

Through Exxar Human Module users can load and possess a mannequin in XR environment by wearing full body-tracking suits and validate all human interaction focused activities in XR for accurate analysis.

Yes, you can perform validations by introducing a mannequin in VR which is calibrated to our real body. With this all interaction activities with the model will be highly accurate. This means that all posture-related issues (effecting reachability and accessibility) can be accurately assessed.





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