Navantia ’ s Shipyard 4 . 0 model overview

Resumen Vistazo general del modelo de Astillero 4.0 de Navantia Date Received: June 3rd 2017 Fecha de recepción: Junio 3 de 2017 Date Accepted: October 18th 2017 Fecha de aceptación: Octubre 18 de 2017 Navantia’s Shipyard 4.0 model overview 1 Engineering and Innovation Vice-President NAVANTIA. Spain. Email: arecaman@navantia.es DOI: https://doi.org/10.25043/19098642.165 Ship Science & Technology Vol. 11 n.° 22 (77-85) January 2018 Cartagena (Colombia) 78 All developed countries are concerned with maintaining industrial and innovation capabilities as engines of their economies. After the economic crises of recent years, the contribution of Manufacturing to the GDP and the added value as a percentage of the GDP of most developed countries has fallen. Understanding that there is no sustained economic growth without a strong and innovative industry, there is a global approach to improve industry performances by leveraging new technologies, known as the Fourth Industrial Revolution. If manufacturing productivity is to be increased and business costs reduced, reforms will have to be made. In shipbuilding, the Colombian Government has developed a plan to for the productive development of the key industrial sector for the Colombian economy, whose purpose is to enhance the competitiveness and productivity of the industry. Th at Plan is called “Plan de Transformación Productiva1” (Plan of Productive Transformation). In it, the Shipbuilding Industry is identifi ed as one of the key industrial sectors. In order to meet these requirements of improving productivity and reducing business costs, Navantia has implemented the Shipyard 4.0 model. Th is model aims to apply and optimise the Fourth Industrial Revolution technologies for shipbuilding applications and is being implemented at Navantia’s Ferrol shipyard as part of the program to build the Spanish Navy’s next-generation F110 frigates. By innovating in core business areas, the Shipyard 4.0 model provides the basis for optimisation of the shipbuilding processes. 1 https://www.ptp.com.co/portal/default.aspx Navantia‘s Shipyard 4.0 Model seeks to deliver the following outcomes • Creation of a sustainable shipbuilding industry that will deliver the Navy ś future capability through an incremental low risk process; • Modern facilities that will deliver internationally competitive products; • Modern ICT (Information Communication Technologies) infrastructure that will support the ships’ digital twins; and • Creation of new skilled workforce able to face the new industrial challenges. Th roughout the western world new industrial paradigm has surfaced called the Factory of the Future. Th e Factory of the Future is enabled by the so-called Fourth Industrial Revolution, as a result of technological advances in digitalisation and connectivity. Th e challenges originated by this revolution must be addressed without delay: • standardisation and reference architecture; • managing complex systems; • comprehensive broadband infrastructure for industry; • safety and security; • work organisation and design; • training and continuing professional development; • regulatory framework; and • resource effi ciency. Introduction The Fourth Industrial Revolution: Industry 4.0 Ship Science & Technology Vol. 11 n.° 22 (77-85) January 2018 Cartagena (Colombia) Recamán

All developed countries are concerned with maintaining industrial and innovation capabilities as engines of their economies.After the economic crises of recent years, the contribution of Manufacturing to the GDP and the added value as a percentage of the GDP of most developed countries has fallen.Understanding that there is no sustained economic growth without a strong and innovative industry, there is a global approach to improve industry performances by leveraging new technologies, known as the Fourth Industrial Revolution.
If manufacturing productivity is to be increased and business costs reduced, reforms will have to be made.In shipbuilding, the Colombian Government has developed a plan to for the productive development of the key industrial sector for the Colombian economy, whose purpose is to enhance the competitiveness and productivity of the industry.Th at Plan is called "Plan de Transformación Productiva 1 " (Plan of Productive Transformation).In it, the Shipbuilding Industry is identifi ed as one of the key industrial sectors.
In order to meet these requirements of improving productivity and reducing business costs, Navantia has implemented the Shipyard 4.0 model.Th is model aims to apply and optimise the Fourth Industrial Revolution technologies for shipbuilding applications and is being implemented at Navantia's Ferrol shipyard as part of the program to build the Spanish Navy's next-generation F110 frigates.By innovating in core business areas, the Shipyard 4.0 model provides the basis for optimisation of the shipbuilding processes.Th is industrial model, often termed Industry 4.0, has four axes: • vertical integration in a modern factory, aiming to integrate the process from the workshop/ deckplate to top management; • horizontal integration with Customers and Vendors; • end-to-end engineering to cover the complete value chain; and • skilled personnel that respond to the new needs.
Th e Industry 4.0 doctrine is highly applicable to the naval shipbuilding industry, which combines heavy steel construction work with the most advanced electronics to produce technologically complex products.Naval vessels will benefi t greatly from this innovative approach.

Introduction
Navantia has recently completed the study and analysis of the Industry 4.0 model [2] for adaptation to shipbuilding.Th is adaptation has been termed "Astillero 4.0" -in English Shipyard 4.0 -and is currently being implemented.During this phase, projects are being executed to consolidate a range of diff erent technologies with the aim of inserting them in the future ships and systems.Although it is a Navantia initiative, the main project targeted in this implementation phase is the Spanish Navy F110 Program.
Th e Shipyard 4.0 vision has been presented by Navantia to a range of diff erent forums in Spain, including directly to the Spanish Navy.Th e vision is outlined in two elements: digitalisation, which is the technological driver of the vision; and the collaboration between all relevant stakeholders which this allows.

Key Elements
With transformative digital technologies, Navantia's Shipyard 4.0 will develop new processes for obtaining the hundreds of systems that compose our ships.

• Digitisation of all the workshops' machinery
will enable vertical integration through information systems allowing optimisation of the machines' maintenance and energy consumption.• Collaborative robotics will allow people and robots to work together.A range of tasks will be automated, from the more diffi cult and repetitive, to quality control, or even administrative work.• Additive manufacturing, or 3D printing, will allow the manufacturing of complex component pieces from a 3D model with the same simplicity as printing on sheet of paper.• Virtual reality will allow the development of a 'digital twin' or ship 0 to be created and fully explored ahead of physical construction.• Virtual modelling will optimise the ships and their systems' confi gurations in advance as well as simulating the production processes required for their fabrication.Th e digital twin will be the cornerstone of all the process along the whole lifecycle of the ships.• All of these measures will directly translate into a signifi cant improvement of personnel health and safety, environmental protection, and an optimisation of energy consumptions.

Technological Development
Th e use of these technologies will allow the full participation of the workshops, docks and diff erent areas of the shipyard with the technicians and administrative personnel -vertical integration.Th e Shipyard 4.0 physical facilities will evolve alongside the information and communication systems, allowing connectivity between people, products, and machines, creating a cyber-physical space.
Th e use of on-line production processes sensors and insertion of specialised robots, as well as big data and data mining, will allow for the earlier identifi cation of defects and errors to be corrected in advance.Th is will greatly improve quality assurance and reduce the risk inherent in complex programs.
In a similar manner, these new technologies will allow a continuous fl ow of information and materials between the shipyard (centre of gravity of the digital ecosystem) and its customers and Th is level of horizontal integration allows collaborators to have completely diff erent engagement rules based on a previously unthinkable level of transparency and scope.Th is allows the incorporation of universities, and scientifi c and technological centres in addition to the more traditional vendor network.
As a direct consequence, Shipyard 4.0 will be very fl exible in the make-control-buy 2 process, which could be adjusted based on the shipyard workload and the facilities capacity, while maintaining the integration function powered by the new digital technologies.
Eff ective application of the new technologies will require the contribution of engineering (End-to-End Engineering) in all aspects of the Shipyard 4.0, in the vertical and horizontal axes, and through the life of the ships.In this way, Systems Engineering will be used routinely as an integral part of the build process and the shipyard will evolve as a System of Systems.
Critically, all of the intelligence and connectivity on board the ships and their systems during their construction will be kept after delivery to the owners, allowing engagement between the smart ship and Shipyard 4.0 through their life by enabling smart sustainment and new business models.

The 'Digital Twin'
In this highly complex environment -for both the technical and management fi elds -the digital twin or ship zero will be the cornerstone of the Shipyard 4.0 concept.It will allow the simulation of new products and process developments in virtual work stations.Th is includes personnel considerations and the reduction of health and safety hazards.[3] Moreover, the digital twin will be the key element 2 Make: fabricated at the shipyard for enabling the make-control-buy 3 strategy of the Shipyard 4.0.It will allow the diff erent stakeholders to work simultaneously on the digital twin from two perspectives: that of the customer and that of the vendor.Th is work will happen throughout all product phases: innovation, design and construction, and through the vessel's life.
Obviously, in order to develop the potential of the digital twin and the massive amount of information gathered through the ship's life, it will be necessary to innovate in the rules of engagement between the shipyard, its vendors, and its customers.Th is innovation will start from the reference customer: the Spanish Ministry of Defence.
Navantia is currently an international benchmark in the Naval shipbuilding industry because of the  In a similar manner, the Shipyard 4.0 implementation plan must be based on a progressive plan in all Shipyard 4.0 axes (end to end engineering, vertical and horizontal integration and personnel).Th e materialisation of the concept requires real projects which consolidate the associated technologies and reveal the potential of the digital transformation of Navantia shipyards.[4].Navantia is currently implanting the following specifi c projects: • Modelling and simulation of the production process; • Digital management of the shipyard plant;

Navantia and Ferrol Implementation
Naturally, fully realising the potential of digital technologies will require changes to physical facilities.For this reason, Navantia has begun a series of shipyard facilities improvement studies.
Particularly notable is the Ferrol modernisation project to meet Shipyard 4.0 requirements for the Spanish Navy's F110 future frigate.
As a result of these studies, Navantia has defi ned a preliminary confi guration for the Ferrol shipyard.Key features in this confi guration are: • Building a new dry dock which will allow the complete building of the ships; and • Construction of the specialty workshops (piping, HVAC, etc.) next to the dock to minimise distances and optimise the material fl ow.
Th e required surface to undertake the shipbuilding process will be reduced by 50%.
Th e new physical facilities will be enhanced with the most modern digital infrastructure, which will not only allow for monitoring of production within the shipyard facilities but also the vendors' production in their own plants.Th is will provide greater visibility to the shipyard, as well as greater transparency to the customer throughout the build process.
Navantia is working on the Information and Communication Technologies (ICT) architecture that will support this digital revolution.
Navantia's Shipyard 4.0 vision could be of great benefi t to Colombia as well as Spain.As outlined in this document, this vision is currently being consolidated on specifi c programs (e.g.F110 in Spain -it could also be applied to Colombia future frigate program) but goes far beyond the ships themselves.
Th is initiative fi ts in the strategic view of the Government of Colombia as developed in the Plan de Transformación Productiva.Th e implementation of Shipyard 4.0 in Colombia would require an incremental approach in order to generate the benefi ts without unnecessarily increasing the inherent technological risks in naval shipbuilding.
In this sense, a two batches approach to the shipbuilding program as planned by Colombia would allow signifi cant benefi ts through a progressive implementation plan of Shipyard 4.0 ensuring that the shipyard, the supply chain, universities and technological centres remain tied to the program development inserting innovation all the way through the program.
In order for this vision to be realised in Colombia, the following will be required: -A designer integrated with the shipbuilder to accommodate production and sustainment needs; -A supply chain engaged in the innovation process by improving the connectivity of their products through each batch; -A redesign of existing facilities to maximise the shipyard productivity levels, allowing them to reach or exceed international benchmarks; -Defence Science and Technology Group (DSTG), universities and technological centres developing the key technologies that need to be inserted in the ships and in Shipyard 4.0; and -ICT partners that will support the challenges of the vertical and horizontal integrations.The following conclusions can be drawn: 1. Colombia is determined to develop the capacity of its shipbuilding industry.For that, strategic decisions regarding the development of the infrastructure, clustering of the industrial network, local supply chain engagement and cooperation with referenced shipbuilders through transfer of technology agreements are tools for the shipbuilding growth in the long term.2. Spain commenced a shipbuilding enterprise reform plan in the 1980s, which has consolidated Navantia as a global leader in the shipbuilding industry.Navantia is ready and willing to assist Colombia now to implement its own plan.3.In the pursuit of continuous improvement and innovation, Navantia has defined the Shipyard 4.0 Model that will enhance the company capabilities in the coming years.
The model is holistic and is applicable to all relevant stakeholders.The Shipyard 4.0 implementation plan is collaborative and will be driven by specific innovative projects that will consolidate the Fourth Industrial Revolution in shipbuilding technologies.4. Navantia is convinced that Shipyard 4.0 can be applied in the Colombian shipbuilding industry in its endeavour to develop an innovative and productive shipbuilding enterprise.This customisation process needs to be incremental to ensure that naval program outcomes are successfully delivered.
Thanks to my colleagues in Navantia, in Spain and Australia, who have contributed to this paper in all aspects.
The merits are really theirs.

Shipyard 4. 0
Augmented reality will allow workers easy access to all of the information about any specifi c component.• Data mining will allow the extraction of meaningful information from a large amount of data (big data) generated in the horizontal and vertical integration of Shipyard 4.0.• Th e Internet of Th ings will connect all Shipyard 4.0 stakeholders: people, products, and facilities within the physical shipyard or around the world.Th is could include geographically disperse supply chains, or allow the connection of shipyards in Ferrol and Adelaide, for example.• Th e secure cloud will remove the borders for storing, computing, and exchange existing information.• Cybersecurity will ensure the protection of all information.

3
Control: procured by the shipyard but with an increased oversight .Buy: procured by the shipyard

Fig. 5 .
Fig. 5. Navantia´s vision of evolution from stand-alone Products to System of Systems