Kul-24.

4130
Shipyard engineering

Lecture 1-1:
Shipbuilding process

Applied Mechanics
Marine Technology
Lecture in course contents
Production Introduction
planning

Shipbuilding process and

ship yard productivity

Outfitting

Design process
and materials
managements

Hull production
Objectives, contents and literature
• Learning objective:
– Understand shipbuilding process
– Recognise shipbuilding process stages
– Know the basic terms of shipbuilding process
• Contents:
– Production strategy
– Theoretical shipbuilding model
– Shipbuilding process stages
– Basic terminology
• Literature
– Laivatekniikka. Räisänen toim., 2000, Kappale 30
– Ship production, Storch et al., SNAME, 1995, Chapter I-II
Production strategy

• Main challenge of production strategy:

– The aim of the production investment is to create a
competitive advantage for the company, not just the
best factory in the world

• If own factory does not create a competitive

advantage, it is better to buy a product than to
make yourself
Product?

• Material versus immaterial (car vs. experience)

• Product vs. Services (ship vs. repair service)
• Consumption vs. investment
• Part vs. product package
• One-off vs. standard part
• Standard, customized, personalized ...
• Product family, variation, extension
• Combination vs. selection
Production objective

• The aim is to achieve at the same time a good

– productivity (added value / cost,…)
– controllability (lead-time)
– flexibility (to manage overproduction)
– sensitivity
– capital efficiency (efficient use of capital)
– loaned capital / productivity -ratio (profit, cost)
– quality
 Production customisations level
Design intensity Warehouse vs. design-to-order
and customisation

One-off-a kind
products or systems

Standard, volume products

Production efficiency/Repetition
Customisations level
Volume vs. one-off production Before order – After order

Design Design Design Design Design

Fabrication Fabrication Fabrication Fabrication Fabrication

Assembly Assembly Assembly Assembly Assembly

Distribution Distribution Distribution Distribution Distribution

WAREHOUSE PACK-TO-ORDER ASSEMBLY-TO FABRICATE-TO DESIGN-TO-ORDER

Customisation level
Product and type of market

Characterics Demand stable Demand dynamic

Product life cycle Long (2+ Y) Short (<1.5 Y)

Product variety Low High

Forecasting error Small (5-10%) Big (40%)

Contribution to
Small (5-10%) Big (30-60%)
margin
Lead-time for make-
6-12 months 1-14 days
to-order
Development trends of Finnish and European
maritime industry
• Strong networking of the shipbuilding
– Shipyards focuses on their core
business and utilize sub-contractors,
modular solutions and integrated
suppliers
– Extreme example is an assemble yard
concept
• Suppliers focus on developing their
own product and supportive activities
• The ship's owners look for new
solutions to reduce life cycle costs
and improve competitiveness
Theoretical shipbuilding model

The production function

qt = q (Kt, Lt, Et)

Cumulative
production
qt = production rate at time t
Kt = capital utilization rate at time t Time
Lt = labour utilization rate at time t
Et = efficiency effects due to

Production rate
production rate change at time t

manning
Time
Labour utilisation rate

• Labour utilization rate Lt is defined as

quality-adjusted labour
– Ship sequence number (experience effect*)
– Number of workers (manning level)
– Change rate of the workers number
– Length of the work day (overtime)
– Workers' skill level

*) Experience curve effect (Experience Curve)

• Costs is reduced by a constant amount each time the
accumulated production is doubled
• In shipbuilding industry, this constant is normally 5-10%
Efficiency effects

• Distractions affect the efficiency effects Et

– Incomplete or missing plans
– Interruptions in the use of labour
– Interruptions in support functions
– Worker morality
Stages of Shipbuilding process
1. Concepts design
2. Initial design
3. Basic design
4. Component definition and acquisition
5. Coordination design
6. Product hierarchy and work breakdown structure
7. Detail design
8. Material requisition
9. Part fabrication (hull and outfitting)
10. Unit production (module, element, etc.)
11. Block outfitting (sis. Steel outfitting)
12. Painting of blocks
13. Block outfitting
14. Hull assembly
15. Area outfitting
16. Commissioning, delivery
Ship production terminology

• Block, sub-block, part assembly, and part

• Space and Area
• System, sub-system, and
equipment/part/component
• Product and pre-fabrication
• EMO, EM, and JM –outfitting
• Turn-Key -delivery
Block, sub-block, part assembly, and part
• Block: the largest construction unit, a part of part of
the ship's hull or superstructure, applied in
production. For example, at the Turku shipyard
block can have dimensions of about 40x30x15 m
and weigh 600 t.
• Sub-block: The blocks are assembled from sub-
blocks. Sub-block typically includes some welded
equipment (bushings, pipes and cables),
implemented before painting
• Part assembly: sub-blocks are assembled from
different part assemblies, such as bulkheads,
welded sections, floors, etc..
• Part: blocks and part assemblies are done from
components, such as plates, stiffeners, brackets,
collars, collars. It is typical that the parts are made
by cutting a raw plate and profiles
Space and Area

• Area: the combined space such as a cabin area or a nightclub. The

area can also be a vertical entity such as a staircase or engine
casing. The area consists of one or more spaces. The essential thing
is that the area is uniform and it is not composed of unconnected
spaces. The area definition is a yard-specific and it is affected several
factors such as the location, shape, size, consistency, content and the
amount of work.

• Space: a unique space of ship such as the cabin, bridge, engine

room, air conditioning room, etc.. Space alone or together with other
spaces compose the area.
System, sub-system, and equipment/part/component

• System: a functional subsystem of the ship such as air

conditioning, power generation, propulsion system. Typically, the
system extends more than one area, either by serving them, or just
passing through.
• Subsystem: The system consists of sub-systems (components of
the system). Subsystems such as air conditioning canal, cable
trays, a main generator, shaft.
• Equipment / part / component: Equipment are functional parts of
subsystems such as canal damper, main generator, support
bearing. Parts and components are smaller installation units such
as screws, nuts, fuses, etc. The definition of part and component is
not unambiguous.
Product
• Product is the results of the productication i.e. the part of the ship or the
work task.
• The product has always
– Content, definition
– Work unity

• The product is always associated with

– input and output:
– electrical, plumbing and heating, alarm, etc.
• The product has an interface or interfaces with other products.
– Interfaces are more and less physical. The product may be a part of
hull, space, area, system, or any combination of the above.
– The product must be clearly understood, thus it can not be
indefinable or abstract thing.
Pre-fabrication
• Pre-fabrication is a part or a set of parts which are
manufactured in the workshop, not onboard. Modules are
prefabricated functional entities. The division is based on
the applied production technology:
– In machinery outfitting, the examples of the pre-fabrication are
separator unit, fuel pump unit, cooling equipment unit, piping set,
sewage treatment plant, control panels.
– In the interior outfitting, the prefabrication is call as a module. WC
and cabin units are sophisticated examples, where the installation
is completed at a workshop. The module is only connected to the
ship's systems in block or area outfitting stage.
– Other examples for interior outfitting are wall and roof modules,
large furniture for restaurants such as bar.
EMO, EM, and JM –outfitting
(Abbreviation applied in Finnish shipyards)

• EMO -outfitting
– Sub-block outfitting done before the painting

• EM - outfitting
– Block outfitting done before the painting. Contains work
phases, which might ruin the painting such as welding and
flame cutting. The installed outfitting equipment are selected
so that they will not damaged due to blasting and painting.

• JM - outfitting:
– Block outfitting done after the painting
Turn-Key -delivery

• Turn-key- delivery includes

– Design
– Material requisition
– Fabrication
– Implementation to the ship
– Testing and commissioning

• Sometimes, the term is applied broadly considering the

fabrication and installation as Turn-key delivery. The
trend of activity is towards the exact definition.