Digital twin technology is a hot topic in manufacturing, but in an industry as complex and highly discrete as shipbuilding, the question of how to implement it effectively demands practical answers. The approach taken by Jiangsu Haizhongzhou Shipping Industry Co., Ltd. is to complete a full "pre-construction" in the virtual environment.
The foundation of this "pre-construction" is a 3D digital model that exactly matches the physical ship. This model goes far beyond just geometric shapes — it contains complete engineering information, including block division, weld layout, outfitting installation sequence, piping routes, cable trays, and more. Every pipe and every weld in the model possesses its own engineering attributes, directly corresponding to subsequent manufacturing and inspection processes.
Based on this model, the process engineering department carries out comprehensive virtual simulations. Whether the lifting path of large equipment interferes with already installed structures, whether pipe routing meets expansion compensation requirements, and whether sufficient space is left for construction access — all these issues are verified one by one in the virtual environment. Compared to traditional paper-based reviews of 2D drawings, 3D simulation is several times more effective at identifying problems, while the cost of resolving them is a fraction of what it would be during actual construction.
Construction guidance represents another layer of digital twin application. 3D process documents replace traditional 2D drawings and are pushed directly to workstation terminals or mobile tablets. Workers can rotate, section, and measure the 3D model, intuitively understanding assembly relationships. Complex joints are accompanied by 3D animations demonstrating assembly sequences — essentially providing a "digital master craftsman" at each workstation to guide operations. This method has proven particularly popular among younger workers, significantly shortening the learning curve.
The digital twin also extends to dynamic control of the construction process. Actual progress data from block fabrication, coating, outfitting, and berth assembly stages are fed back into the model, creating a "virtual vs. reality" comparison. Planned milestones are color-coded — green for on schedule, yellow for early warning, red for delayed — allowing managers to grasp the entire vessel's construction status at a glance and providing a stronger basis for scheduling decisions.
To be realistic, establishing a digital twin system is not accomplished overnight. It requires deep collaboration and data standardization across multiple departments — design, process engineering, production, quality, and others. However, the practices at Haizhongzhou Shipbuilding have already demonstrated that the resulting reduction in design errors, increase in construction efficiency, and enhancement of traceability capabilities are more than sufficient to justify the investment.
