konecranes heavy lifting/ports – engineering · company presentation 9 2008 sales by industry....
TRANSCRIPT
Ports – Engineering Esa Ojapalo, May-2009 1
Esa Ojapalo, design manager, Konecranes Ports Technology
KonecranesHeavy Lifting/Ports – Engineering
Ports – Engineering Esa Ojapalo, May-2009 2
Heavy Lifting / Ports - Engineering
• Konecranes in brief• Company history• KC Heavy Lifting/Ports, business overview
– Seaborne trade, World merchant fleet, Trade growth, Container Throughput– Ports Products reflected to certain market drivers
• Engineering at KC Heavy Lifting/Ports– Delivery Projects– Order to Delivery– Engineering Process Team
• Product Structure in different phases– Initial structure– Sales Product– Offer Product– Engineered Product– Manufactured Product– Start-Up Product– Warranty time– Maintenance and Service
• Design Environment
Ports – Engineering Esa Ojapalo, May-2009 3
Service
Standard Lifting
Heavy Lifting
Business Areas of Konecranes
Company Presentation 4
Company Values
• Trust in PeopleWe want to be known for our great people
• Total Service CommitmentWe want to be known for always keeping our promises
• Sustained Profitability We want to be known as a financially sound company
Company Presentation 5
Konecranes in figures
• Sales EUR 2 103 million (2008)• Over 9 900 employees in 485
locations in 43 countries• One of the Largest Crane Builders
in the World• The Largest Crane Service
Company in the WorldGroup Headquarters
Hyvinkää Finland
Company Presentation 6
Shanghai, ChinaSpringfield, USA
Vernouillet, France Hämeenlinna, Finland
Markaryd, Sweden
Annual Production
• More than 30 000 cranes and rope hoists• Tens of thousands of chain hoists• 600 Heavy Duty Cranes• 500 Lift Trucks & Reach Stackers• 360 000 Equipment under Maintanance• 60 000 Electric Control Systems
Hyvinkää, Finland
Company Presentation 7
Worldwide Network
Company Presentation 8
Sales Splitby Business Area and Region, %
(29) (34)
(54)
Company Presentation 9
2008 Sales by Industry
Company Presentation 10
Group Research and Development
• Multi-Company Research Projects in Electronics and Materials
• Participation in International Standard and Norm Development Work
• University Co-Operation• Dedicated R&D Laboratories• Product Development
– Hoist and Machinery Units– Electric Motor Technology– Crane Control and GPS Systems – Control Software and Automation– Maintenance Technologies– Crane Designs– Strength Analyses– Crane Engineering Tools
Company Presentation 11
• 1910 The Electrical Motors Repair Shop KONE Oy is Formed
• 1933 Production of EOT (Electric Overhead Travelling) Crane Starts
• 1936 Production of Wire Rope Hoists Starts
• 1950 First Harbor Crane• 1960 First Preventive Maintenance
Contract • 1973 International Expansion Starts
(First Acquisition into USA in 1983, France 1985, UK 1991, Germany 1997)
• 1988 KONE Cranes Division is Formed• 1994 Independence from KONE Oy• 1996 KCI Konecranes Shares Listed on
the Helsinki Stock Exchange
Company History
Company Presentation 12
Company History
• 2002 Factory in Shanghai, China and JV in Japan
• 2004 Reach Stackers and Lift Trucks added to Product Range
• 2005 Acquisition of Stahl CraneSystems, Germany
• 2006 Acquisition of MMH Holding, Inc.• 2006 GPS Positioning Systems added to
Product Range (Savcor One)• 2007 Straddle Carrier added to Product
Range• 2007 Factory in Lingang, China• 2008 Twelve acquisitions to strengthen
company global position
© 2009 Konecranes. All rights reserved.
KONECRANESHeavy Lifting
PORTS
Ports – Business Background Esa Ojapalo, May-2009 14
Background 1/5: Seaborne trade
• Seaborne trade in 2005 was 6 600 million tons, which of– 39% consists of Dry Bulk (wheat, coal, ore, woodchips…. etc.)– 38% consists of Liquid Bulk (crude oil, liquid-gas…. etc.)– 23% consists of General Cargo (break bulk, container cargo)
Container Terminal Focus 2015. 2006. One Stone Intelligence GmbH. Germany.
Ports – Business Background Esa Ojapalo, May-2009 15
Background 2/5: World Merchant fleet
• World merchant fleet was 960 million dwt at the end of 2005, which of– 354.2 dwt in oil tankers– 345.9 dwt in bulk carriers– 111.1 dwt in container ships– 96.2 dwt in general cargo ships– 52.5 dwt in other ships
Other ships5 %
15 %
General cargo ships10 %
Container ships12 %
Bulk carriers36 %
Oil tankers37 %
Review of Maritime Transport. 2006. United Nations. New York and Geneva.
Ports – Business Background Esa Ojapalo, May-2009 16
Background 3/5: Seaborne trade growth
• Over the past two decades seaborne trade increased by 3.5% in average p.a.
– General cargo grew faster, 5.5% p.a.– Container cargo grew 9.6% p.a
Seaborne Trade Growth 1985 - 2005
Container Terminal Focus 2015. 2006. One Stone Intelligence GmbH. Germany.
Review of Maritime Transport. 2006. United Nations. New York and Geneva.
International Monetary Fund. October 2007. World Economic Outlook Database.
• World Merchant fleet grew 7.2% in 2005– Oil tanker fleet grew 5.4%– Dry bulk carrier fleet grew 7.9%– Container ship fleet grew 13.3%
World Economic GrowthGDP annual change
0.00 %
1.00 %
2.00 %
3.00 %
4.00 %
5.00 %
6.00 %
1980 1984 1988 1992 1996 2000 2004 2008
Ports – Business Background Esa Ojapalo, May-2009 17
Background 4/5: World Throughput Forecast to 2013
• Container handling at deep-sea and river ports has grown tremendously– Average annual growth rate 10.7% from 1995 to 2005– Between 2005 and 2007 growth rate 11.3% per annum in average– From 2007 to 2008 4.9% despite of the global depression– In 2008 the container cargo was some 150MTEUs which generates 520MTEU
throughput– The effect of the global depression will be recovered in 4...5 years
World Port Throughput 1990 – 2007 and forecast to 2013
Container Terminal Focus 2015. 2006. One Stone Intelligence GmbH. Germany.
ARGCTO 2008 addendum. 2009. Drewry Shipping Consultants Ltd. UK.
TEU – Twenty-feet Equivalent Unit = 1 x 20’ cargo container. 1 x 40’ cargo container equals 2 TEUs
Ports – Business Background Esa Ojapalo, May-2009 18
Background 5/5: Container Throughput in Terminals
• How the container traffic affects to the need of container handling?
Container Terminal Focus 2015. 2006. One Stone Intelligence GmbH. Germany.
TEU – Twenty-feet Equivalent Unit = 1 x 20’ cargo container. 1 x 40’ cargo container equals 2 TEUs
Ports – C.Terminal Products Esa Ojapalo, May-2009 19
Container Handling Equipments
Ports – Engineering Esa Ojapalo, May-2009 20
Engineering at KC Heavy Lifting/Ports
• Delivery Projects of Engineered Products• Ship-to-Shore Cranes• Shipyard Cranes• Shipboard Cranes• Bulk Handling Cranes• Certain Type of Container Yard Cranes (ASCs, RMGs)
– Engineering and design work 1 …. 15 person work-years• Depending if repeat order or completely new product order
• Delivery Projects of Standard Products• RTG Cranes• Straddle Carriers• Lift Trucks
– Engineering and design work less than 1 person work-years
• Typically always certain part of tailoring is needed• Local regulations• Country-specific or harbour-specific practices
Ports – Engineering Esa Ojapalo, May-2009 21
Typical Crane Delivery Project
• Divided in 6 phases (from order to delivery)• Project start-up• Engineering• Procurement (Purchase and Manufacturing)• Shipment• Assembly, Erection and start-up• Handing over and warranty
• Engineering Process Team• Project Manager
– Arranges the engineering kick-off meeting• Chief Engineers (Mechanical, Electrical)
– Manage the engineering processes, Approve designs• Leading engineers
– Specialists in certain problem area, team leaders (components, structures, etc..)• Design engineers, design teams, sub-contractors• Project secretary
Ports – Engineering Esa Ojapalo, May-2009 22
Product Structure 1
• Initially Product Structure consists of– Tasks (eg. design task, but also research, development, …etc.)– If product template exists
• Uncomplete or complete sub structures (assembly items)• Items
• In target to fulfill• Product sales features• Customer’s requirements
Ports – Engineering Esa Ojapalo, May-2009 23
Product Structure 2
• Sales Product– Product Platform engineering
• Product features• Known Solutions• Main modules• Preliminary or finalized dimensioning• More or less accurate cost estimation for pricing
• Offer Product– Offer engineering phase– Combination of
• Product features• Customer requirements• Deviations
– Typically not a complete structure (in project type of products)• Main modules• Stuctures of similar earlier products or modules if exist
Ports – Engineering Esa Ojapalo, May-2009 24
Product Structure 3
• Engineered Product– Engineering Phase of Delivery Project– Engineering data
• Detail engineering• Analysis, Selections, etc..• Sub-assemblies, components, items, unique structure
– Cost estimation getting more acurate
• Manufactured Product– Completion phase– Combination of
• Purchased assemblies and components (supplier, subcontractor)• Manufactured features• Traceability of parts, raw materials and work phases
– Unique product structure– Accurate cost level of product known
Ports – Engineering Esa Ojapalo, May-2009 25
Product Structure 4
• Start-up Structure– Effect of transport, erection and final operation environment– Start-up procedures
• Crane automation, Control programs, crane PLC– As-built after hand-over– Cost of delivery known
• Warranty Time Structure– Cumulative operation history– Warranty items– Improvements, corrections– Total delivery project cost known
• Maintenance Structure– Cumulative maintenance history– Spareparts, Modernizations
Product Data Management
Sales productOffer product
Engineer product structure
OrderOffer
Manufacture product structure
Features by manufacturing
Purchase item features
Start-up structure
Maintenance structure
Erection
Transportation
Start-up
Procuration Delivery Hand over
Maintenance structure
Operation history
Maintenance history
Modernisation
Sparepart items
Product completionVirtual product
Sparepart items
Modernisations
Operation and service
Disposal
Generic product structure Unique product structure
Delivery Contract
Delivery scope
Technical spec
Customer scope items
Customer requirements
Product features
Engineering data
Sub assemblies
Components, items Warrantytimestructure
Warranty over
Warranty items
Pro
duct
stru
ctur
e co
mpl
exity
Sales
Ports – Engineering Esa Ojapalo, May-2009 27
Items
• Items in product structure– Manufactured item
• Features (technical, strength, cost, etc…)• Virtual model (3D model, drawings, etc…)• Maker
– Purchase item• Features• Virtual model• Supplier
– Assembly item• Sub structures and items• Features• Virtual model• Supplier
– Selectable item• For selecting suitable item after engineering has done
Engineered item purchaced
Engineer product structure Manufacture product structure
Manufactured item Subcontractor=
Purchase items Supplier=
V
V
Selectable item
= Selection 1 (item) Sel. 2 (item) Sel. 3 (item) … Sel. n (item)V V V
Purch.item
Manuf.item
= Project no. V Selected item
V Supplier
Assembly item
= Item a Item b Item c …Item n
V V V = Project no. V Assembly item
V Subcontractor
Project no.
Project no.
V
V
Selectable item is an engineered generic item which is actually a structure where the relation between items is ”or” instead of ”and”. Selection choice point is after engineering has done and ready. It decreases the need of re-engineering due to sourcing or any other reason.
Ports – Engineering Esa Ojapalo, May-2009 29
Design Environment
• Design tools at Konecranes Heavy Lifting/Ports– AutoCAD+CADMill
• Main mechanical design tool for engineers– Movex
• ERP for KC Ports BA delivery projects• Project management• Project finance control• Item management• Procurement
– VertexDM• Document management
• Design Development at Konecranes Heavy Lifting/Ports– Design tool integration– Product Data Management– Harmonized Tool Palette for all Konecranes Business Areas
NOT JUST LIFTINGTHINGS, BUT ENTIREBUSINESSES
© 2009 Konecranes Plc. All rights reserved.
Ports – Product overview Esa Ojapalo, Jan-2009 31
THANK YOU!