www.meyerwerft.de January 2012 N o 09 Fireworks greet Disney Fantasy The DISNEY FANTASY is the second ship that the shipyard has built for Disney Cruise Line in Orlando, Florida. The new ocean giant left the dock on 8 January 2012 to be greeted with fireworks. The DISNEY FANTASY is 340 metres long, with a tonnage of 130,000 gt, and can take 4,000 passengers. As with the DISNEY DREAM, special features include the water coaster and the virtual portholes in the inside cabins. Highresolution cameras on the outside of the ship project real-time pictures into the interior. >>
Disney Fantasy >> After leaving the dock, the new ship then moored at the shipyard s outfitting pier, where it went through numerous tests. This was followed by the remaining interior finishing work and final tests and acceptance procedures in the shipyard harbour. Only a few days after leaving the dock, the DISNEY FANTASY was conveyed down the river Ems to the North Sea; after being handed over to the owner in February, she will reinforce the Disney fleet. Reorganisation of Materials Management and Purchasing As of 1 July 2011, the organisation of the Materials Management and Purchasing division run by Ralf Sempf at MEYER WERFT was brought in line with the constantly increasing challenges of recent years. Purchasing has been divided into two departments run by executives reporting directly to Ralf Sempf. are also directly answerable to the Head of Materials Management and Purchasing as administrative functions, which in some cases also support other companies belonging to the Group. In the Laser Centre the tugger train provides the flow line with material Tugger trains for seamless material supplies SUPPLIER MANAGEMENT, PURCHASE CONTROLLING, SUB PROJECT MANAGEMENT PURCHASING U. Sap, B. Schmitz HEAD OF MATERIALS MANAGEMENT/PURCHASING R. Sempf CONTRACTS U. Janßen, J. Benner We already introduced our tugger trains in the last issue of IM DIALOG. As part of the lean shipbuilding system concept, they safeguard optimised material supplies to our production activities, providing material among others to both sides of the flow line in the new building 11 of the Laser Centre. COST BREAKDOWN ANALYSIS, CIP TRAINER B. Koch NEWBUILDINGS K. Lübbers GENERAL PURCHASING J. Thieke Newbuildings is run by Klaus Lübbers and focuses on the procurement of systems, plants and components for the ships being built at our yard. Klaus Lübbers has been working in Purchasing since 2005; until appointed Head of Department, he was mainly involved in setting up our supplier rating system, establishing Purchasing Controlling and various other purchasing-related issues. General Purchasing is run by Johann Thieke and deals among others with the procurement of all capital expenditure items and means of production, material stocks, IT requirements etc., and is also responsible for the purchasing of steel and aluminium sections/blocks as well as concluding contracts for work and labour, for example when manufacturing activities are outsourced. Johann Thieke has been employed by the shipyard already since 1980 and was responsible among others as Head of Group for Purchasing and provisionally also as Purchasing Manager at NEPTUN WERFT. Together with these two purchasing departments, Ralf Sempf s division also includes External Production/Deadline Monitoring (Edzard Körte) and the Warehouse (Ewald Jürgens). Other important tasks EXTERNAL PRODUCTION, DEADLINE MONITORING E. Körte WAREHOUSE E. Jürgens NEPTUN WERFT G. Pallutz This includes Purchase Controlling and Sub Project Mangagement Purchasing, under the auspices of Beate Schmitz and Uwe Sap, together with the function of the CIP trainer and responsibility for cost structure analysis; these tasks are performed by Bertram Koch. Another important area is Contract Management which is responsible for all legal issues in the context of our purchasing contracts. These tasks are performed by Udo Janssen who will also be assisted by Jens Moritz Benner as of 1 January 2012. New Head of Purchasing in Rostock As of 1 January 2012 Gunnar Pallutz has taken over as head of NEPTUN WERFT s Purchasing division. The affiliated companies MEYER WERFT and NEPTUN WERFT are pursuing the same purchasing strategy. The common MEYER NEPTUN PORTAL, for instance, shows this very clearly. We are sure that by modifying the structures of the division Materials Management and Purchasing, we have taken due account of the constantly increasing challenges of the market, putting our corresponding activities on a futureoriented basis. The tugger train consists of a traction unit and several C-frames. Rolling load carriers can be pushed into the C-frames and raised hydraulically while on the move to ensure that the load carrier rollers have no ground contact during transport. The load carriers contain synchronised, section-specific outfitting material that is fitted to the sections within a period of four hours. The wide range of outfitting material includes among others cable trays, ventilation tubes and water pipes. An outfitting cycle amounts to four hours. The flow line starts moving every three hours: for a whole hour, it moves all sections on from one outfitting station to the next, all at the same time. When a tugger train reaches the target address on the flow line, the C-frames are low-ered and the rolling load carriers can be uncoupled from the frame by a foot coupling and marshalled between the building supports in a cycle buffer. The cycle buffers contain only the synchronised outfitting material for the next section. This safeguards seamless material supplies for the sections while keeping material stocks low. While the sections flow from one outfitting station to the next, the section outfitting staff take the mobile load carriers from the cycle buffer and position them in a defined marshalling area in front of the section. It is also possible to lower the load carriers onto the section using a crane. The tugger train delivers synchronised, sectionspecific outfitting material In addition, rolling shelves are available at defined points containing small parts such as screws, clamps and spring washers. The shelves are filled by a Kanban system. At the end of a cycle, the empty load carriers are collected by a tugger train; the material needed for the section can be taken from the interim buffer and made ready at the section. This cycle is consistently repeated. 2 IM DIALOG IM DIALOG 3
First suppliers workshop at the seatrade europe 2011 The 2011 Seatrade Europe Cruise and River Cruise Convention was held in Hamburg at the end of September. Together with many companies in the cruise industry, MEYER WERFT and NEPTUN WERFT were also present with a stand. For the first time, a Suppliers Workshop was held during the convention, with participation of the Fincantieri, STx France, MEYER WERFT and NEPTUN WERFT shipyards. The aim of this workshop organised by Hamburg Messe und Kongress GmbH at the initiative of MEYER WERFT was to put active and potential new suppliers in contact with purchasing staff from the participating shipyards. The new hall 11 with the flow line start of ProDuction in the new hall 11 During the Family Day on 30 October 2011, MEYER WERFT celebrated the opening of the new production hall 11 of the Laser Centre. This project saw capital expenditure of more than 35 m by the shipyard in the Laser Centre. Measuring 361 metres in length and 45 metres in width, the building has a new synchronised flow line for outfitting sections with an integrated turning device. This is used for outfitting sections measuring up to 30 x 30 metres in size with pipes, cable trays, airconditioning ducts and far more in a four-hour cycle. Following the initial words of welcome, Ralf Sempf gave the participants an insight into the current situation on the cruise market, after which the Purchasing Managers of the shipyards presented their companies. More than 200 representatives of 130 companies, including already active suppliers for the shipyard industry as well as firms from outside the branch, then had an opportunity to establish or enhance their contacts to the shipyard purchasers in ten-minute speed dating sessions. The concept of this event was based on our Regional Day event, offering participants a chance to network among themselves in addition to the speed dating. The Suppliers Workshop gave the participating companies a special incentive in the fact that while generally competing with each other, here the shipyards had come together in a joint effort to find new suppliers. This makes sense: in the end, all shipyards that build cruise ships have to procure more or less the same materials and services. In the aftermath of the event, the various talks have to be evaluated with a view to new potential cooperation. A subsequent debriefing session attended by representatives of the shipyards and those responsible for the event at Hamburg Messe und Kongress GmbH drew a positive conclusion all in all, while agreeing that the concept needs further refinement for possible future events. Ralf Sempf gave an insight into the current situation on the cruise market Speed Dating with NEPTUN WERFT The integrated turning device 4 IM DIALOG IM DIALOG 5
Order for Research Vessel Sonne The first LNG tanker START OF CONSTRUCTION OF environmentally friendly gas tanker CORAL ENERGY Computer animation of the new research vessel SONNE On 19 August 2011, Annette Schavan, Federal Minister of Research and Johanna Wanka, Minister for Science in Lower Saxony, signed the contract with NEPTUN WERFT in Rostock-Warnemünde to build and manage the new deep-sea research vessel SONNE. The Federal Ministry of Education and Research thus continues to renew the German research fleet. The new ship is intended to replace the 36-year old deep-sea research vessel SONNE in 2015. The new SONNE will serve to enhance marine research and also secure jobs in Germany s maritime industry. The contractor in this project is Tiefsee FS GmbH & Co. KG, a consortium consisting of NEPTUN WERFT (Rostock) and the shipping company RF Forschungsschiffahrt (Bremen), after winning a European tender procedure in the face of strong competition. The vessel will be built by NEPTUN WERFT in Warnemünde. The new ship clearly enhances the technical possibilities for future projects by the coastal research institutes and universities. It will be operating primarily in the Indian and Pacific Oceans. Both oceans have a great influence on the global climate, so that corresponding research is gaining considerably in significance. But the SONNE will also be addressing other issues of particular scientific and social significance, looking especially at exploiting marine raw materials Manfred Müller-Fahrenholz (Managing Director NEPTUN WERFT), Klaus-Dieter Mayer (Managing Director RF Forschungsschifffahrt) Annette Schavan (Federal Minister of Research) und Johanna Wanka (Minister of Science in Lower Saxony ) and the human impact on the eco systems. The new research vessel will be energy efficient and therefore particularly environmentally friendly. MEYER WERFT and NEPTUN WERFT are building their first LNG tanker as a new, innovative vessel type with so-called dual fuel engines for the shipping company Anthony Veder (Rotterdam/NL). Work on building the gas tanker which will carry liquefied natural gas (LNG) began on 9 November 2011. The vessel named CORAL ENERGY is approx. 156 metres long and 22.70 metres wide with loading capacity of 15,600 m³ LNG, which can be transported at temperatures of down to minus 164 C. It operates at a cruising speed of 15.80 knots; thanks to the dual fuel engines, it can run on both Marine Gas Oil and also on so-called boil-off gas (evaporated LNG) which is generated during the journey when the tanks heat up. The solution designed by MEYER WERFT therefore combines appropriate utilisation of the boil-off gas with low-emission propulsion of the ship. Delivery is planned for the fourth quarter 2012. NEPTUN WERFT in Rostock will be responsible for building and particularly for outfitting the ship. This important order is MEYER WERFT s first for LNG tankers, thus making a crucial addition to the portfolio of 55 LPG and LEG gas tankers already built by the company. Here the shipyard concentrates its activities on medium-sized vessels. We see great future potential in this market. At the same time, we are able to expand our expertise further with regard to environmentally friendly propulsion systems, says Managing Partner Bernard Meyer. The LNG tanker CORAL ENERGY Main Particulars Coral Energy Length 156 m Breadth 22.7 m Tank capacity 15,600 m³ Min. tank temperature -164 C Max. tank pressure 4.5 bar (g) Speed 15.8 kts Main engine Wärtsilä 6 IM DIALOG IM DIALOG 7
Meyer Werft at the Marintec 2011 1,000 CGT 80,000 70,000 60,000 50,000 40,000 30,000 20,000 10,000 0 ORDERBOOK NEW ORDERS COMPLETIONS 1998 1,916.00 748.00 1,129.00 China Commercial Shipbuilding Activity 1999 2,796.30 1,988.40 1,158.00 2000 3,554.90 1,981.10 1,150.00 2001 4,765.70 2,656.80 1,368.00 2002 5,943.13 2,668.53 1,561.10 2003 9,326.87 5,235.03 2,604.00 2004 12,589.00 5,691.00 2,929.00 2005 15,629.00 6,067.00 4,343.00 2006 25,701.00 13,366.00 5,148.00 2007 50,22.,00 28,92.00 6,638.00 2008 62,011.00 13,864.00 9,053.00 2009 54,359.00 7,113.00 12,520.00 2010 48,923.00 16,102.00 18,801.00 Source: CESA 1st half 2011 47,875.00 3,856.00 9,406.00 Over the last ten years Chinas has massively increased its shipbuilding activities. The Chinese shipbuilding suppliers have developed in a similar way. Many of these companies presented themselves at the Marintec 2011. For many years the competitive pressure has been increasing also in our market segment of large cruise ships and other special-purpose ships. Hence we in Purchasing are forced ever more to investigate the potential of the Asian procurement market. An opportunity to do just that was offered at the Marintec 2011, the biggest marine trade fair in Asia which took place in Shanghai from 29 November to 2 December 2012. Winning contracts for newbuildings has become ever more competitive. Hence it has become increasingly difficult for us to pursue our existing purchasing strategy, which is focused on national and European suppliers. For this reason it is indispensable for us to look beyond European borders and to investigate to what extent the Chinese and the rest of the Asian procurement market could be of interest to us. We learnt a lot from attending this trade fair, including the fact that all components needed to build a ship can be procured in Asia, and especially in China, starting from the smallest light bulb right through to the most complex systems to be installed on the ship. There is altogether great potential in the procurement of components for our ships from Asian suppliers. When it comes to buying in Asia, we are certainly aware that we are faced with a couple of challenges we have to master. As a conclusion it remains to say that the Asian market may become interesting for us. Of course we are trying hard to pursue our existing purchasing strategy in cooperation with our European suppliers. However, it will take quite an effort to make this happen. Imprint Editor: MEYER WERFT GmbH Industriegebiet Süd 26871 Papenburg Layout: eskalade werbeagentur GmbH info@eskalade.de www.eskalade.de Photos: Disney Cruise Line Ingrid Fiebak Fotografie MEYER WERFT Seatrade Hamburg Further information www.meyerwerft.de