disney dream is nearing completion hard struggle for

August 2010 | No 06
DISNEY DREAM IS NEARING COMPLETION
The final stage of the Disney Dream‘s building process has begun
by mounting the last of a total of 80 blocks. In the coming months
until the delivery, the focus of the construction work will be on the
interior finishing of the ship.
Some 800 partner companies contribute to the construction of the
Diseny Dream and her sister ship, the Disney Fantasy.
Last year the keel laying of the Disney Dream was celebrated when
the first block was put in place. The 128,000-gt ship features 1,250
luxury cabins.
HARD STRUGGLE FOR NEW ORDERS
The German shipbuilding industry is in deep crisis. Some enterprises
rich in tradition have already disappeared from the „map of shipyards“, others have found new owners and almost all are undergoing
a process of extensive restructuring and cost saving to improve their
chances of surviving in competition. > page 2
www.meyerwerft.de
August 2010 | No 06
www.meyerwerft.de
HARD STRUGGLE FOR NEW ORDERS
COST MUST COME DOWN
With an order backlog of six large cruise ships to be delivered by the end of 2012, MEYER WERFT is in a comparably better situation than many other shipyards.
But we also need to get follow-up orders in the next
months to guarantee full employment of all crafts.
With a market share of more than 25% for cruise
ships we are among the top 3 shipyards in the world
to build these demanding vessels. We have reached
his outstanding position jointly with you, our for
the most part long-standing supply partners. In order to survive on this market in the future as well, it
is necessary to undertake the greatest efforts.
However, with an external share of the costs of a
cruise ship of more than 75%, we are especially dependent on support from you. Jointly with you, we
are facing the extreme challenge to drastically reduce the costs of the plants, systems and goods and
services to be provided by you, of course without
any impairment of the quality of our ships.
The few newbuilding projects available on the
market are extremely contested. The price level for
newbuilds at which our customers are prepared
to award contracts is extremely difficult and corresponds to the level of 2003 or 2004. How hard
contracts are being fought for is clearly evidenced
by the unfortunate loss of the prospective contracts
with Princess Cruise Line.
With the lean construction methods that have been
or are being introduced in our production areas,
we are creating the necessary preconditions for
sustainably reducing costs at our suppliers as well.
Key words such as access to the building site in the
areas to be worked on, shorter processing/finishing
times, improved planning ability of preassembly
and many other feasible goals describe excellent
starting points for cost reduction for your and our
benefit. The results from the first finishing areas
on our newbuilding S 677, Celebrity Eclipse, clearly show the advantages of the changed method of
construction.
With the investments into state-of-the-art production facilities made in recent years, we have set the
points in the field of engineering to survive competition in the future. Moreover, we are working
at full speed to make all areas of the shipyard „leaner“ and more productive. We have the ambitious
goal to improve our profitability by 50% in the next
three years. The excellent results from the first production areas where we have introduced cycle-based flow production following the methods used in
the automotive industry show that we are on the
right track with the measures we have taken.
IM DIALOG
However, we need even more, exceptional contributions on your part to drastically reduce the cost
of the cruise ships to be built by us.
Support us to enable us to build these marvellous
products in Papenburg in the future as well! In turn,
we will offer you a long-term cooperation with a
reliable partner.
FIRST REGIONAL DAY OF NEPTUN WERFT
About 150 participants made the first regional day of NEPTUN WERFT a big success.
Apart from a description of the current market position, the participants were given information on
the shipyard‘s building programme and possibilities
for cooperation. Moreover, the companies were
given an opportunity to present themselves to the
yard‘s executive staff in short meetings. The tours of
the yard also met with lively interest.
The successful event is another step towards building and extending NEPTUN WERFT‘s regional network of competent and capable suppliers.
NEPTUN WERFT WINS NEWS ORDER
NEPTUN WERFT in RostockWarnemünde will build a new
river cruise ship for Viking River
Cruises.
The ship will have 72 cabins and two suites, and will
be approx. 135 m long, and11.45 m wide. It will
have a draught of approx. 1.60 m. Delivery to the
owner is scheduled for June 2011. Moreover another two options have been agreed for delivery in
the spring of 2012.
As early as in March this year A-ROSA Flussschiff
GmbH had placed an order with NEPTUN WERFT for
their third river cruise ship to operate on the Rhine.
© Viking River Cruises.
IM DIALOG
August 2010 | No 06
www.meyerwerft.de
INNOVATION AWARD
LASER TECHNOLOGY 2010
Frank Boekhoff, Guido Pethan, Hermann Lembeck (from left to right)
On 5 May 2010, Arbeitskreis Lasertechnik e.V. and the European Laser
Institute ELI awarded the Innovation Award Laser Technology 2010 in
the town hall of Aachen.
The winner of the award which includes prize money of €10,000 was Dr. rer. nat. Keming Du, managing director of EdgeWave GmbH with the innovation „Q-switched INNOSLAB lasers for high-quality
micro-machining“.
The third place was awarded to Hermann Lembeck
and his team at MEYER WERFT Laserzentrum GmbH
in Papenburg. The innovation concerns the „Laser
hybrid welding of thick steel plates with disc lasers
in shipbuilding“.
The members of the project management:
Dipl.-Ing. Hermann Lembeck, plant manager,
Dipl.-Ing. Guido Pethan, project manager investments, Dipl.-Ing. Frank Boekhoff, head of trials,
R&D
IM DIALOG
CABIN CONSTRUCTION ON THE FLOW LINE
EMS Pre Cab
EMS PreCab now also makes allowance for the trend towards a more efficient process shaping and general optimisation of its in-house processes.
Cabins for cruise ships on EMS PreCab‘s new flow line
Under the aspect of „Lean Construction“ our cabin
supplier is making the change towards a cycle-based flow production.
EMS PreCab‘s conventional cabin production follows the so-called workshop principle. A cabin is
manufactured at a stationary workplace in the production hall. It takes not more than two days for a
team consisting of a maximum of three employees
to assemble a cabin. Hence the work package per
cabin is quite big for each employee. Consequently
the production output differs drastically per team,
which may affect quality and quantity of the end
product.
This is where the change in production comes in. It
is imperative to build the cabin more quickly, more
uniformly, at lower cost and better quality, and to
make the production process more transparent. To
reach this goal EMS PreCab has invested in a flow
line. It is 96 m long, 10 m wide and operates at a
speed of 3.5 m/s. It is clearly defined in 22 cycles
which component has to be installed at a certain
time. In this way 24 cabins can be manufactured per
shift so that a completely assembled cabin leaves
the flow line every 20 minutes.
The transparency in the production process thus obtained has shown that a new logistic system is also
necessary. For this reason EMS PreCab will soon also
require a just-in-time delivery by its suppliers. The
correct material quantity must be available at the
right time and in the right quality. And it is important for the suppliers to put the material packages
together in accordance with the sequence in which
the material is required at the flow line prior to installation. These are essential prerequisites to ensure a smooth production process.
An epidemic failure in the supplier‘s production
process has a direct impact on the flow production
at EMS PreCab since these failures are not detected
until the material is unpacked for installation at the
flow line. Hence quality checks must be conducted
while the material is still on the supplier‘s premises
so as to avoid production downtimes at EMS PreCab.
It takes joint efforts by EMS PreCab and its suppliers
to reach the goal of „Lean Production“. A flow
production – and hence a substantially optimised
production – is merely feasible by the best possible
fine-tuning of all involved processes.
IM DIALOG
August 2010 | No 06
www.meyerwerft.de
WORKFLOW MANAGEMENT FOR ELECTRONIC INVOICE PROCESSING
In business relationships, values such
as timeliness and reliability form the
basis for successful cooperation. Reliability is of special importance. In
order to further improve reliability
with regard to accounts payable to
suppliers, we have installed electronic invoice processing at the beginning of this year.
What is behind all this?
Electronic invoice processing is a tool
used in accounting to automate the
entire invoice processing workflow,
i.e. the workflow from invoice registration to invoice verification to
payment and archiving. The scanned invoices are
registered, read and if applicable sent to the relevant auditing sites via the so-called job router, a
web-based tool for online processing. Hence there
is no delay due to the submittal of the invoice to
the recipient as the electronic invoice is available
immediately.
Essential advantages are:
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Automatic reading of invoices, which makes timeconsuming manual registration unnecessary
System allows processing in parallel of invoice
verification and release
Stand-in rules, e.g. for holidays, are stored and
automatically implemented by the system
Transparency: The invoice verification status is
available at any time
MEYER NEPTUN PORTAL
Until mid-July 2010 more than 2,000 companies
have got registered in our portal. Of these, 750
companies are mebers of the regional network of
MEYER WERFT.
In the regional network of NEPTUN WERFT which
went online in May this year more than 50 companies have become members to date.
IM DIALOG
Pre-processing of invoice and transfer to JobRouter
workflow
One question that remains is what is the benefit for
our suppliers? We know, reliability is not a one-way
road. With the improved handling of payments we
prove that we are your reliable partner. Please help
us with this by printing your invoices on neutral paper having no background colours or shades. Do
not staple the invoices or send us duplicates. Also
invoices printed on a needle printer are in most
cases hard to scan, and need to be re-edited, which
leads to more delays.
FLYING THE FLAG - MAKE MEYER
WERFT YOUR REFERENCE
You have been a long-standing, reliable partner of
MEYER WERFT who supports shipbuilding in Papenburg? You are already a member of the shipyard‘s
supplier network and contribute to the construction
of state-of-the-art, premium cruise ships? Then we
offer you to underscore the relationship you have
with the shipyard and the ships being built there:
use a MEYER WERFT website banner for your web
presence! Demonstrate to your staff, your (potential) customers and other partners that you are a
member of MEYER WERFT‘s shipbuilding network.
Click on www.meyerwerft.de/Service
LEAN SHIPBUILDING
OPTIMISATION OF THE SHIP DEVELOPMENT PROCESS
Cycle control plan
”Nothing is so good that it cannot be made even
better.“ That old saying is confirmed time and again,
especially if you start questioning what you‘re doing yourself, because despite our more than 200
years of experience in shipbuilding, this also is true
in respect of the workflows at our shipyard. For this,
we have a strong partner on board: Porsche Consulting. Following the optimisation of the workflows
in production, the focus was set to the ship development process in a second step, concentrating on
the planning and design phase.
In successive work steps, an in-depth analysis of
the ship development process has been performed,
unproductive times have been revealed and set
workflows defined. We understand the ship development process to comprise the entire range from
the first inquiry by the customer to delivery of the
vessel. The lean maxim must apply to all areas, to
each process step: whatever does not serve the creation of value is lost time, is waste. In addition to
cost optimisation, considerably shorter construction
time is achieved.
It is obvious that with this approach we cannot
stop at describing the known procedures including
all special rules that have crept in. With regard to
this, processes have been and are still being cleared
up and simplified and reliability is created, e.g. by
transparent and defined work sequences.
We have not yet completed the optimisation process. Nevertheless, the lean construction idea is al-
ready showing first effects, e.g. in production: the
cycle control planning is improving cooperation
and this entails shorter throughput and waiting
times. In the technical planning, suppliers are involved earlier and closer in newbuild projects, e.g.
to verify feasibility from the point of view of engineering, scheduling and costs. The impact on you as
our partner is not inconsiderable. On the one hand,
throughput times in production and thus your calculation basis change, less waiting times occur due
to the close time coordination and your imputed
mark-ups, e.g. for waiting times, may no longer
apply. On the other hand, more partner companies
are involved closer and longer in newbuild projects.
This gives you a chance to incorporate new engineering solutions into the project at a very early stage.
It is our joint task to master the challenges of the
present and the future. The lean shipbuilding system provides us with the right tools for this.
DELIVERIES IN 2010
Delivered to date:
- AIDAblu: 4 February 2010
- Celebrity Eclipse: 15 April 2010
In January 2011 the Disney Dream will enter into
service.
IM DIALOG
August 2010 | No 06
www.meyerwerft.de
DISNEY CRUISE LINE EXHIBITION IN VISITORS CENTRE
A new attraction has been waiting for visitors to
MEYER WERFT since February 2010: Disney Cruise
Line‘s (DCL) new exhibition.
> Imprint
Editor:
MEYER WERFT GmbH
Industriegebiet Süd
26871 Papenburg
Layout:
eskalade werbeagentur GmbH
[email protected]
www.eskalade.de
Photos:
MEYER WERFT, Ingrid Fiebak Fotografie, Jörg
Düwel, Ute Müller
Further information
www.meyerwerft.de
In cooperation with Papenburg Tourismus GmbH the shipyard‘s Visitors Centre
provides information on the cruise ships under construction.
The exhibition is partitioned in the three sections “Dream”, “Design” and
“Build”. It starts with the introduction of the cruise operator Disney Cruise
Line.
In the second section various exhibits such as the mock-up of the “AquaDuck”,
the first water coaster ever on a cruise ship, give the visitors an idea of what
the new cruise ships “Disney Dream” and “Disney Fantasy” look like. In the
third and last section of the exhibition DCL provides information on outstanding developments and events from the years 2007 through to 2012, complete
with photos and videos covering the construction of the new ships.
It is understood that the visit to the shipyard ends with a highlight, namely a
view into the covered building dock where the “Disney Dream” is being built.
She is one of two ships MEYER WERFT is building for Disney Cruise Line.
A visit to the yard including a tour headed by a competent guide and a visit to
the Disney exhibition will approximately take 2 hours.