Global

Industrialisering
&
Produktkonfigurering

Virksomheder i netvrk
Trondheim Maj 2004

Agenda
1. Introduction to Aalborg Industries
2. Why Product Configuration ?
3. The Standardisation Process
4. Challenges
5. Demonstration of Configuration Tool

Aalborg Industries
Facts

Global market leader (Marine boilers and energy equipment)

Owned by Danish investors group headed by Axcel

Production area:

80,000 m in the Aalborg Industries Group

Employees AI Group :
in Aalborg

1,412
455
225 blue-collar workesr
230 white-collar workers

Quality certifications

ISO 9001:2000 Quality Management System (since 1989

ASME Boiler and Pressure Vessel codes S
and NBBIs R since 1986
LRS, DNV, BV, NK, RINA, CS, KS, ABS, AT.

Aalborg Industries
History

1912
1919
1930s
1937
1944
1978
1980
1988
1990
1995
1997
1997
1998
1999
2000
2000
2001
2002

Aalborg Shipyard established

First Aalborg boiler (Scotch marine type)
New types of boilers developed
Danish J. Lauritzen Holding (shipowners) acquired Aalborg Shipyard
First power station boilers built
First after sales service company established in Singapore
Production of large industrial power plants
Burner company acquired (KB burners)
Heat exchanger / incinerator company acquired, A/S Vesta
The Sunrod Group (marine boilers and heat exchangers) acquired from ABB
Zurn Energy Division (HRSG & Keystone Package Boilers) acquired from Zurn
Industries Inc.
Pipemasters Oy (UNEXTM marine and industrial boilers) acquired from Finnyards Oy
Name change to Aalborg Industries as per 1st September 98 for all group companies
Acquisition of Wiesloch (thermal fluid heating systems), The Netherlands
Aalborg Industries acquired by Danish investors group headed by Axcel
Acquisition of ATA Combusto Tcnica, Brazil boilers from Mitsubishi, Japan.
Subsidiary Ciserv AB, Sweden, sold to Wrtsil, Finland
Subsidiary Aalborg Industries Inc., USA, sold to Daekyung Machinery &
Engineering Co. Ltd., Korea

Aalborg Industries
Global overview
Office locations
Aalborg

Stockholm
Rauma
Dalian

York

Pusan
Kobe
Tokyo

Rotterdam

Qingdao
Shanghai
Dubai

Houston

Singapore
Jakarta
Petrpolis
So Paulo

Hong Kong

Jakarta
Indonesia

Petrpolis
Brazil

Qingdao
China

Aalborg
Denmark

Industrialization of Boiler Manufacturing

KEDEL
DAMP

Damp
Vand

Three pass smoke tube boiler

Steam space
Saturated steam

Saturated
water

Steam outlet

Pass 3
tube

Pass 2
tube
Flue gas to stack

10 bar 184 oC

220 oC

400 oC
1000oC

2000 oC

Burner

Internal
Reversal
chamber
Oil

Combustion
Air

Feed water inlet

Furnace

MISSIONTM 3 Pass

Aalborg Industries
Business areas

Marine Boilers

Heat Recovery Steam Generators

Industrial Boilers

Heat Exchangers

Inert Gas Systems

Complete solutions
Exhaust gas
economisers
Composite boilers

Oil-fired boilers

Heat exchangers
Coolers
Condensers
Cargo heaters

Inert Gas Systems

Agenda
1. Introduction to Aalborg Industries
2. Why Product Configuration ?
3. The Standardisation Process
4. Challenges
5. Demonstration of Configuration Tool

Aalborg Industries
Manufacturing
Office locations

Aalborg

Stockholm
Rauma
Dalian

York

Pusan
Kobe
Tokyo

Rotterdam
Erie

Qingdao
Shanghai
Dubai

Houston

Singapore

Jakarta
Petrpolis
So Paulo

Hong Kong

Competitiveness
through Standardisation

Quicker and more precise clarification with

the customer

Increased application of prefabrication

(From unit production till mass-produced components)

Increased automation of the order process

Reduction of mistakes.

Stronger purchasing power

(Volume / stock purchase)

Improvement of Business Relationship

with our Customers

Improve the basis for shipyards

competitiveness through:

Improved the communication

Clarification of technical requirements early in project
Fast documentation up-front

Reduction of lead times

Fast response on changes

Fast installation and commissioning

Less faults

3D models of boiler and other major components

In future the Product Configurator allows the customer

to design their boiler plant themselves

Agenda
1. Introduction to Aalborg Industries
2. Why Product Configuration ?
3. The Standardisation Process
4. Challenges
5. Demonstration of Configuration Tool

Overlapping Boiler Products

AQ12
AQ9
AQ10/12W UNEX
CHB
CHS CPH
MISSION
OS
MISSION
OM

MISSION
OL
AQ18

AQ16
MISSION
D

AR4-N AWN

AQ10/16W

MISSION
3-Pass

GCS
KH

MISSION
OC

UNEX BH
AR3C
UNEX B

WPH AT8D

AV14
MISSION
WHR-GT

Pioneer
GE1
Pioneer
AV10GE
GE2
Pioneer AV10DE
DE1

TO1

UNEX G
AV8N

EGE

AV6N

PT

WIESLOCH
TF

AO1 UNEX P
WIESLOCH
EX

AV9

AV4 AV7
AQ2

AQ7

UNEX H

MISSION
MICRO
Boilers in Grey Italic has no sales record in 2001

Grouping of Products
AQ12
AQ9
AQ10/12W UNEX
CHB
CHS CPH
MISSION
OS
MISSION
OM

MISSION
OL
AQ18

AQ16
MISSION
D

AR4-N AWN

AQ10/16W

MISSION
3-Pass

GCS
KH

MISSION
OC

UNEX BH
AR3C
UNEX B

WPH AT8D

AV14
MISSION
WHR-GT

TO1

UNEX G
AV8N

EGE

AV6N

PT

WIESLOCH
TF

AO1 UNEX P
WIESLOCH
EX

AV9

AV4 AV7
AQ2

AQ7

UNEX H

MISSION
MICRO

Boilers in Grey Italic has no sales record in 2001

Standardisation into
Product Families
MISSION AQ12 AQ10/12W UNEX CHS CPH AQ9 MISSION
CHB
OS
OM

MISSION
OS

MISSION
OM

MISSION AQ16 AQ10/16WUNEX

KH GCS
OC

MISSION
OC
AV8N AV6N

UNEX EGE PT
G

MISSION
XW

AR4N

AWN

MISSION
OL

AR3C

MISSION
3-Pass
AV4 AQ7 AQ2 AV7

MISSION
XS

MISSION
OL

AQ18

UNEX UNEX
BH
B

MISSION
2-Pass
UNEX
H

WIESLOCH
TO1
TF

MISSION
TFO

UNEX
WIESLOCH
AO1
AV9
P
EX

MISSION
XTF

Configuration of Boiler Plants

(Complete Systems)

Consolidating Best Practice

Predefined Concepts and well-defined Options

Container ships

Crude carriers

Gas tankers

Cruise ships

Koncept # 9
Koncept # 7
Koncept # 2
Concept # 1
2 x MISSION OM

2 x MISSION1OL
x MISSION XW
2 x MISSION1OL
x MISSION1XW
x Power Panel
2 x MISSION1OL
x MISSION1XS
x Power Panel
1 x Feed Water Pumps
1 x MISSION1XW
x Power Panel
1 x Feed Water
1 x Pumps
Circulation Pump
1 x Power Panel
1 x Feed Water
Pumps
1 x Circulation
Pump
1 x Fuel Oil Unit
1 x Feed Water
1 x Pumps
Circulation
1 xPump
Fuel Oil Unit
1 x Circulation
1 xPump
Fuel Oil Unit
1 x Fuel Oil Unit
..
..
Service Steam

WHR
Boiler
(without
Steam
space)

Oil Fired
Boiler

Feedwater
Pump Unit
Circulation
Pump

Bottom Tank

Intelligent
Product Configuration Tool

Customer
Options
Class Rules
Engineering
Experience
Production
Experience

Product Configuration Tool

Consistent and
well-proven Solutions

Documentation and Drawings

from the Product Configurator

lat
u
c
l
Ca
e
c
i
Pr

ion

Documentation

Configuration tool

Dra
w

ing

Product Family Master Plan

Heat and steam generating system

[1..2]

Control system
The preferred class of water and steam section depends on the required stam pressure and the required
steamflow. In theory all the classes can be designer for the required pressure range and steam flow range but
the plate scantlings will be increase dramatically. The typical relations are expressed in the following table

NB: Attributes for "Heat and steam generating

system" are specified on seperate sheet (as
"Functional attributes").

Boiler

PLC

Relay

Type [oilfired, gasfired, WHR, combi ]

Microprocessor
Steam pressure [barg]
Maker [York electronic]

Orientation [Vertical, horizontal]

Boiler
Control
panel
Motor
starter
center

1,2

Burner position [Top, Side]

[1, 3]

Relay
Panel

Sandbluss [none, SA2.5]

1,2

Paint color [Red, Silver (heat resistant]

[1]

1, 20

Pressure part
1,10

[1]

Boiler equipment

Motorstarters

0,1

Controlsystem

Cabinet seperator

Auto/manuel
Switch

Auto/manuel
Indicator

[1]

Forced circulation system

0,1

Space

Main steam system

1..5

Chamber

x
x

Relationships between service level and transformer

If the required service level is essential a

transformer and a cabinet separator is
mandatory

Ground detection

Relationships between power and the

ampmeter

Use of Ampmeter is optional but if

the power is greater than 11Kw a
transformer is mandatory

Ampmeter

Terminal
Remote start/stop

Switch

Exhaust system

Part-of model

25-120
x

Water treatment
0,1

[1]

Hour Counter

Water level control

0,1

[0,1]

Transformer

0,1

[1]

8-20

Running
indicator

Water / steam system

[1]

1-8
x

Start Stop

Auxilleries

[1]

Steam Flow [t/h]

24

Motorstarters

[1]

18

Service level [Essential, important]

Burner system

[1]

10

Drum

0,1

[0,1]

Water & steam section

Kind-of model

Rules and relations

Variability has a Cost!

Component

Variability

Maker [..., ....,....]

Dimension [..., ....,....]

Variability
Auxilleries
[0, 1]

Circulation pump unit

Variability

Control system

Relay

PLC

Microprocessor

Configurable Boiler Plants

supporting Market Demands
Product Family Master
Heat and steam generating system

[1..2]

NB: Attributes for "Heat and steam generating

system" are specified on seperate sheet (as
"Functional attributes").

Boiler

Market

Type [oilfired, gasfired, WHR, combi ]

Orientation [Vertical, horizontal]
Burner position [Top, Side]
Sandbluss [none, SA2.5]
Paint color [Red, Silver (heat resistant]

[1]

Demands

Boiler equipment

[0,1]

Match

Pressure part

[1]

Burner system

[1]

Controlsystem

[1]

Auxilleries

[1]

Configurable Solutions

Water / steam system

[1]

[1]

[1]

Boiler Plants

[1]

[0,1]

Water level control

Forced circulation system

Water treatment

Main steam system

Exhaust system

Sales and Order Execution

ERP System

Configuration tool

Customer

Makes

Has a need

Bill-of-

Bill-of-Material is attached to
the order in the ERP system

Material
Quote
ERP system containing AI items and
operations (cutting, welding, etc.).

Drawing and/
or 3D model

Configurator uses rules

to select a product
family and configure a
valid solution

Product platform rules

(Predefined Standards)

Platform rules refer to

AI items and operation

Item
Catalogue

Operation
Catalogue

Agenda
1. Introduction to Aalborg Industries
2. Why Product Configuration ?
3. The Standardisation Process
4. Challenges
5. Demonstration of Configuration Tool

Challenges
Global Similarities vs. Local Differences
Market requirements (e.g. DIN/JIS flanges)
Material standards (e.g. EN/GB/NK standards)

The configurable product platform is not

complete
To handle partly configurable solutions
The order port folio - long horizon
Repeat orders

Challenges (Cont.)
Order Execution Etc.
Order Execution - AAL
Configured
Boiler Plant

Order Execution - UKB

Order Execution - PUS

Delivered
Boiler Plants

Sales

AAL
TAO

JKT
RIO

Production Sites

Suppliers

Sales and Order Execution

Reference Model
Customer

Sales &
Sales
Support

Scope of Delivery Defined

Orderprocessing

Production
& Materal
Planning

Production

Shipment &
Commissioning

After Sales &

Maintenance

Sales & Order Execution

100 %

Engineering

Concept
Sale
Need
Customer
Interest Phase

Sales Phase

Order Processing
Phase

Customer Order
Recieved

Order Manufacturing
and Delivery Phase

Maintenance Phase
Delivery
Accepted by
Customer

Sales and Order Execution

Reference Model
Customer

Sales &
Sales
Support

Scope of Delivery Defined

Orderprocessing

Production
& Material
Planning

Production

Shipment &
Commissioning

After Sales &

Maintenance

Sales & Order Execution

100 %

Engineering

Customer
Interest Phase

Sales Phase

Order Processing
Phase

Customer Order
Recieved

Order Manufacturing
and Delivery Phase

Maintenance Phase
Delivery
Accepted by
Customer

Sales and Order Execution

Reference Model
Customer

Sales &
Sales
Support

Scope of Delivery Defined

Orderprocessing

Production
& Material
Planning

Production

Shipment &
Commissioning

After Sales &

Maintenance

Sales & Order Execution

100 %
Preferred

Customer
Interest Phase

Sales Phase

Engineering

Order Processing
Phase

Customer Order
Recieved

Order Manufacturing
and Delivery Phase

Maintenance Phase
Delivery
Accepted by
Customer

Sales and Order Execution

Reference Model
Customer

Sales &
Sales
Support

Scope of Delivery Defined

Orderprocessing

Production
& Material
Planning

Production

Shipment &
Commissioning

After Sales &

Maintenance

Sales & Order Execution

100 %
Optimal

Customer
Interest Phase

Sales Phase

Order Processing
Phase

Customer Order
Received

Order Manufacturing
and Delivery Phase

Maintenance Phase
Delivery
Accepted by
Customer

Sales and Order Execution

Reference Model
Customer

Sales &
Sales
Support

Scope of Delivery Defined

Orderprocessing

Production
& Material
Planning

Production

Shipment &
Commissioning

After Sales &

Maintenance

Sales & Order Execution

100 %

Web Sales

Customer
Interest Phase

Sales Phase

Customer Order
Recieved

Order Processing
Phase

Order Manufacturing
and Delivery Phase

Maintenance Phase
Delivery
Accepted by
Customer

Challenges (Cont.)
Shipyards Value Chain
Initial
Design

Purchasing

Boiler Plant Specification

Scope of Supply
Boiler Performance
P&I Diagrams / List of Parts
Installation Manual

Project
Design

3D Boiler Model
Arrangement Drawings
Instructions & Datasheets

Boiler
Installation

As-build Documentation
Maintenance Manual

Agenda
1. Introduction to Aalborg Industries
2. Why Product Configuration ?
3. The Standardisation Process
4. Challenges
5. Demonstration of Configuration Tool

Sales and Order Execution of

Configured Solutions
Request

Create/Update
Request

Non-Configurable
Add-On

Configure
Product

E.g.
- MISSION OS
- Special Pump Unit

Customer
Engineering
TeSAI
Calculate
Price

Documents to
Customer

Create
Documentation

Documents for
Order Execution
Production Sites

Price
Calculation

Demonstration of
the Product Configuration System

Some Experiences
Economical
Initial cost (investment)
Increased maintenance cost
Long term saving

Organisation and workflow

Changed workflow
Changed work contents
Changed skill requirements
Changed organisation

Non-configurable solutions
Difficult and complex
Time consuming
Availability of skill

Thank you for

your attention !