SHIPYARDS AND LAYOUTS

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INTRODUCTION:
The need for continuous technological improvement of shipyard production
processes, with a goal of achieving a concurrent shipyard, requires a very complex decision
making process. For that matter, a large number of different requirements and constraint has to
be analysed and valorised in order to be able to find at least an acceptable solution. Moreover,
finding the optimal solution requires additional analysis and the use of appropriate scientific
methods.

SHIPYARD PRODUCTION AREAS LAYOUT DESIGN:

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PHASE 1:
Identification of closeness ratings of selected shipyard production areas using expert survey method
Within the first phase of the developed methodology the production areas that are directly
participating in the basic shipyard production process are selected. Selected production areas are
given a number and presented in Figure 2 on the example of one modern 5th technology level
shipyard of Group. A combination of these selected production areas directly changes the basic

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 production flow and therefore influences the shipyard production process. In that content it is
necessarily to identify closeness ratings with corresponding weight factors for such areas.

Figure 2 Basic shipyard production areas

1. Steel stockyard 9. Locksmith and craft workshop

2. Plate cutting and forming 10. Outfitting quay with workshops

3. Profile cutting and forming 11. Equipment blasting and painting

4. Plate cutting 12. Area for section assembling and finalizing
5. Panel line 13. Area for section finalizing
6. Subassembly 14. Berth
7. Section blasting and painting 15.Sea.
8. Pipe cutting, forming and outfitting

PHASE 2:
Generation of all possible design solutions of selected production areas by using SLP method
A brief review of the SLP procedure is shown in Figure 3. The SLP begins with
PQRST analysis (step 1) for the overall production activities. The data collection fields including
product, quantity, routing, supporting and time. Should be scrutinized in order to assure the
validness of the input data at the design stage. In the flow of materials analysis all material flows

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 from the whole production line are aggregated into a from-to chart that represents the flow
intensity among different tool sets or work positions. The step of “activity relationships performs
qualitative analysis towards the closeness relationship decision among different work positions.
The step of “relationship diagram positions areas spatially. For those work positions (areas) that
have strong interactions and/or closeness relationships are placed in proximity. The steps of
“space requirements” and “space available determine the amount of floor space to be allocated to
each work position This decision is particularly critical to a workshop design problem due to the
costly clean room floor space and the difficulty in future expansion.

PHASE 3:
Hierarchical modelling with AHP method for optimal design solution selection
In the third phase of the proposed methodology, for optimal design solution
selection, authors suggest using Analytical Hierarchy Process (AHP) [12]. The AHP method as
one of multi attribute decision making approaches. It is a structured technique for dealing with
complex decisions. Rather than prescribing a “correct” decision, the AHP helps the decision

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makers find the one that best suits given constraints and limitations (criteria). So, in order to
select the optimal design between previously selected 20 probable solutions it is necessary to
identify relevant constraints and limitations which this design has to satisfy optimally. The
criteria resulted from design requirements and shipyard’s spatial and technological limitations,
and they are as follows.

SHIPYARD MODERNIZATION

The major shipbuilding yards in Europe are altering their layouts and facilities to achieve
production line goals. The extent of modernization varies widely at various yards. Most yards
have rationalized the flow of steel into and through initial storage, preparation, and cutting areas.
Several yards have production lines for small fabrications, but very few have extended

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production line techniques into the assembly and outfitting of entire ships. This chapter describes
notable aspects of production changes completed or contemplated.

PRODUCTION METHODS:
The principles of production lines and their application to shipbuilding as
described in the Introduction are relatively simple. On the production line, the parts being
fabricated move past a series of work stations, where each employee in turn repeats one specific
process. Each employee performs all the steps required at his station. Tools and supplies are
delivered to the employee at the rate needed to maintain production without delays. After passing
through all the work stations, the product is complete.

STEEL PROCESSING:

Movements from storage and preparation of steel plates and shapes prior to
fabrication has become a highly mechanized production line at almost all large European
shipyards. The unloading of delivery vehicles, rolling the steel to make it straight, cleaning of
mill scale, prime painting, cutting, and delivery to the fabrication areas are generally performed
mechanically by 10 to 30 men. A production line is usually established up to the cutting steps,
with the same sequence of operations described above. Conveyor lines could be extended to load
and unload cutting machines. Each of the preparation operations is usually done by a single
machine at each station along the conveyor carrying either plates, shapes, or both.

ASSEMBLY:

The fabrication of subassemblies and assemblies and erection of the ship hull
were not accomplished as uniformly as the steel processing at the various European shipyards.
For example, the basic operation of welding plates together and then welding stiffeners to the
plates was accomplished in several sequences. The traditional method of placing the plates on
the building way and welding plates together in place was not observed in any European yard
visited, except in special circumstances, such as bilge strakes riveted on a seam. In most yards, a
hull shell area or part of a bulkhead is fabricated in place on a welding platen. Plates are joined,
and stiffeners are fitted and welded individually by manual procedures. Traditionally, workers
are moved from fabrication to fabrication as needed. No other work is done on the fabrication
before lifting it into place in an assembly or on the ship in the building way. Lift weights up to
30 or 40 tons were common using this production method.

ERECTION:

Assemblies fabricated adjacent to the launching way can be lifted into place on
the ship by one or more portal cranes. Almost all U.S. and foreign yards erect ships by the
conventional techniques. The most advanced ship-erecting techniques were observed at the few
yards that were not handicapped by limited weight-lifting capacity. In the well-equipped yards,
lifts of 200 to 600 tons could be assembled inside buildings and transported to the launching way

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or building dock. In the process of transportation of the very large assemblies, a delay was
sometimes planned near the shops, so that outfit could be installed in the assembly. Piping and
foundations were often completed prior to erection; some equipment was installed; and
occasionally even painting and sheathing was begun while the assembly was easily accessible.
The particular method of lifting and erecting these very heavy assemblies is especially important
to this study, because different methods may result in different yard layouts, costs, and benefits.

Production Layout Main Components:

 A steel stockyard
 A steelwork hall
 An Outfitting center
 A pipe shop
 A general-purpose shop
 A paint shop
 A warehouse
 A units and blocks storage area
 An erection area consisting of three platforms
 Outfitting quays
 Lifting and handling installations
 One building accommodating the production supporting services
 One building accommodating the management and administrative offices
 A health and medical service
 A training center
 A building accommodating the catering services
 A transportation station
 A parking

Repair Layout Main Components:

 Docking facilities to be defined of a synchrolift, graving docks or floating docks

 Berths
 A metal shop

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 Hull works
Pipe works
Galvanizing works
 An electrical shop
 A carpenter shop
 A paint shop
 Afloat repair shop
 Lifting and handling installation.
 De-ballasting and sludge treatment plant.
 Management and administrative offices
 Technical services
 A health and medical service
 A training center
 catering services
 A transportation station
 A parking

OVERVIEW OF SHIPBUILDING PROCESS:

In order to build a ship, there are several manufacturing processes comprised of
Design, steel cutting, assembly, pre-outfitting, painting, erection, launching, outfitting, sea trial
and delivery. Shipbuilding process is illustrated in design stages and described in Table 1.

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DESIGN STAGES IN PROCESS OF SHIPBUILDING:

Table 1. Description of shipbuilding process

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MINIMUM SPACE REQUIREMENTS OF A REPAIR FACILITY
2
N. Facility Floor space (m )
1 Docking facilities 29500
2 Berths 26000
3 Steel shop 5000
4 Machine shop 1000
5 Electrical shop 500
6 Carpenter shop 500
7 Paint shop 500
8 Afloat repair shop 500
9 Warehouse 1600
10 Lifting installations 23300
11 Treatment plant 500
12 Administrative offices 400
13 Technical services 400
14 Health-medical service 100
15 Training center 400
Transportation station 1000
16
Parking 1600
17 Catering services 400
Total 92300

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