You are on page 1of 220

SHIP CONSTRUCTION, KEY

NOTES FOR THIS


FASCINATING PROCESS
Roberto Morante Villareal
Marine Engineer & Naval Architect
MATERIALS & MARINE STRUCTURES DEPARTMENT MANAGER
R+D
COTECMAR
Km 9 Via Mamonal - Cartagena
rmorante@cotecmar.com
roberto.omar.morante.villareal@gmail.com
SHIP CONTRUCTION, KEY NOTES FOR THIS
FASCINATING PROCESS
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

SHIPBUILDING
OVERVIEW
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

KEY CONCEPTS
• Long history from the earliest beginnings of mankind
• Very traditional and conservative
• Slow introduction of change
• Basic approach is similar over the years
• Change from wood to iron to steel
• Change from oars to sail to steam with paddlewheel to propeller to diesel
• Factors impacting shipbuilding (compared to automobile and aircraft industry)
Portability of the product - able to pick it up anywhere in the world
Use in world trade - product travels all over the world
Flags of convenience
Foreign labor costs/conditions
World trade growth
National goals (policies)
Relatively low labor skills required for both shipbuilding and ship operation
Labor intensive with easily transferred shipbuilding skills and contribution to balance of payments
makes it an attractive industry for developing countries
Relatively low investment cost.
• Shipbuilding Industry made up of many segments
• Company Types: depends on where you are in supply chain
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

SHIPBUILDING
AROUND THE
WORLD
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

SHIPBUILDING AROUND THE WORLD


Largest shipbuilding countries in world are Japan and Korea
each at about 33% of world demand
Europe comes in at a paltry 10%
China growing fast at 2% per year. Currently about 9%
To maintain its leading position Japan has been able to
improve productivity at an average of 7% per year over the
past 20 years.
Korean productivity is lower at 5% per year but still
impressive. U.S. shipbuilding struggles to improve at an
annual rate of 2 ½%
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

SHIPBUILDING AROUND THE WORLD


THE WORLD FLEET AS A WHOLE

Ship Type Category Number


Cargo Ships 40 000
Passenger Vessels 7 500
Naval Ships and Craft 26 500
Other Self-Propelled Vessels 42 000
Barges and Other Inshore 238 000
Vessels
Total 354 000
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

THE WORLD FLEET OF NAVAL SHIPS AND CRAFT

Ship Type Category Number


Aircraft Carriers 30
Submarines 600
Large Surface Combatants 800
Small Surface Combatants 8150
Mine-Warfare Ships and Craft 1070
Amphibious-Warfare Ships and 5200
Craft
Seagoing Auxiliaries 1700
Service and Other Craft 8900
Total 26 450
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

MARINE COMPANIES AND EMPLOYMENT

Companies/ Employment
Industry Organizations (000s)
Sector Min. Max. Min. Max.
Ship Design 350 450 25 35
Shipbuilding 450 500 335 400

Manufacturing 800 1,000 500 800

Ship Operation 2000 3000 1750 2250

Navies 400 450 2500 2750

Ship Repair 500 600 100 120

Totals 4500 6000 5200 6355

Min/Max Range given due to uncertainty


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

MAJOR SHIPYARDS

Region Countrie Yards


s
North America 1 3
South America 1 1
Western Europe 6 9
Eastern Europe 1 1
Asia 4 25
World Total 13 39
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

MEDIUM-SIZED SHIPYARDS

Region Countrie Yards


s
North America 1 6
Western Europe 8 23
Eastern Europe 4 7
Asia 5 40
World Total 18 76
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

SMALL SHIPYARDS

Region Countries Yards


North America 2 36
South America 5 13
Western Europe 14 144
Eastern Europe 8 37
Africa 2 10
Australasia 1 10
Asia 11 110
World Total 47 347
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

NUMBER OF SHIPS DELIVERED ANNUALLY

Country Number Revenues


(US $ Billions)
USA 5– 8 11
Germany 30 – 40 5
Japan 175 – 250 20
Korea 150 – 200 15
China 20 - 40 2
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

European
Shipbuilding
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

GENERAL OBSERVATIONS
• The shipyards are the few private shipyards that
are still trying to compete in commercial shipbuilding.
• Their productivity is still lower than Japan but is
similar to Korea.
• Some of the shipyards have a very long history (up to
300 years) whereas some are relatively new (50 years)
• They have all been “modernized” but three of them
were the reconstructed East German Shipbuilders and
are the most modern.
•Most shipyards receive some subcontracted structural
blocks. However the Dutch carry it to the extreme of
having hulls subcontracted which they complete.
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Kvaerner Masa Turku Shipyard Findland


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Flensburgh Shipyard Germany


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Volkeswerft Shipyard Germany


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Volkeswerft Shipyard Germany


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Aker MTW Shipyard Germany


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Aker MTW Shipyard Germany


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Aker MTW Shipyard Germany


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Kvaerner Warnow Shipyard Germany


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Asian Shipbuilding
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

GENERAL OBSERVATIONS
•Japan became the world shipbuilding leader in
1960s. Taking about 30 years to accomplish it.
•Japanese shipyards have production workers of 700
to 1,200, of which up to 50% could be in-house sub
contractors.
•Japanese shipyards deliver from 5 VLCCs to 21 Bulk
Carriers per year.
•Japanese shipyard annual steel throughput is from
120,000 to 200,000 tonnes.
•Japanese shipyards, as a block, are the most
automated.
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Kawasaki Shipyard Japan


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

IHI Kure Shipyard Japan


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Oshima Shipyard Japan


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Sanoyas Shipyard Japan


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Samho Shipyard Korea – Hyundai Subsidiary


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Daewoo Shipyard Korea


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Samsung Shipyard Korea


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Hanjin Busan Shipyard


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

GUANGZHOU Shipyard
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

SHANGHAI WAIGAOQIAO Shipyard


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Dalian New Shipyard


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Hyundai Shipyard Korea


The World’s Largest Shipyard
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Hyundai Shipyard Korea


The World’s Largest Shipyard
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

MARKETS, DEMAND AND


SUPPLY IN SHIPBUILDING
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

KEY CONCEPTS:
• Market Share of different types of ships - Large
Medium
Niche
• Changing value over time of different ship types per CGT
• World Shipbuilding capacity is 50% greater than demand
• Result is fierce competition and prices below construction
cost
• This requires subsidies in some form or other from
governments
• Korea has increased its shipbuilding capacity by 50%
over 1994-96, whereas most other countries are
constraining their ambitions
• China is increasing number and capacity of shipyards,
and their capability in size and complexity of ships
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

SHIPBUILDING MARKETS (Continued)


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

DEMAND AND SUPPLY

• 40+ Million GT World shipbuilding annual capacity

• Current annual shipbuilding demand 30+ Million GT

• Demand has peaked, capacity still increasing mainly


in China but in Korea repair yards are being
converted into new construction yards.

• Competition is fierce and shipbuilding subsidies are


required by most countries

• Profit levels are low <5%


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

SHIPBUILDING MARKETS
Markets Segments by Ship Type
LARGE VOLUME
Bulk Carriers
General Cargo
Tankers
INTERMEDIATE VOLUME
Container Ships
RO RO Ships
Chemical Tankers
Ferries
Reefer Ships
NICHE VOLUME
Passenger /Cruise Ships
Car Carrier
LPG Carrier
Oil/Bulk/Ore
LNG Carrier
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

SUPPLY (Continued)
• Hyundai, with 6 drydocks and 16,000 workers
produces 60 to 70 ships per year.
• Daewoo, with 3 drydocks and 8,000 workers
produces 30 to 40 ships per year
• Japanese shipyards focus assembly on 1 dry-dock
and produce 6 to 8 ships per year.
• General Dynamics with two shipyards and 14000
workers produce 4 ships per year.
• Newport News Shipbuilding with 18,000 workers
produce one aircraft carrier every 4 to 5 years plus a
few submarines
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

FACTORS EFFECTING SHIPBUILDING MARKETS,


DEMAND AND SUPPLY
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

FACTORS AFFECTING SHIPBUILDING MARKETS,


DEMAND AND SUPPLY
• Freight rates and scrapping rates depend on surplus
Tonnage.

• Surplus tonnage for tankers is reducing and, of course, is


impacted by the double hull requirement

• Surplus for bulk carriers is at ten year higher.


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

DESIGN
FOR
PRODUCTION
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

DESIGN AND PRODUCTION MUST WORK INTERACTIVELY

cost
determined Design Production

created

time
• concurrent
• interactive
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

DFP PRINCIPLES
There are two main principles for DFP for ships, namely 1)
all design should strive for simplicity, and 2) all design should
be the best suitable for a given shipyard facility.
These can be further expanded as follows:
Simplicity in Design
•reduction in joint weld length,
•minimum number of parts,
•minimum number of parts to be formed,
•part standardization,
•reduction of part variability,
•minimum fitting/fairing of erection joints,
•elimination of need for highly accurate fitting,
•integration of structure and outfit,
•elimination of need for staging, and
•consideration of access.
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

DFP PRINCIPLES (Continued)


Matching to Shipyard Facilities
•checking that blocks and machinery package units and
outfitted blocks are within shipyard lifting capability,
•assembly and block sizes fit panel line, workstations and
door openings,
•use maximum plate sizes and corresponding block breaks
to minimize connecting joint weld length, and
•maximize design for in-shop versus on-ship work.
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

DFP IN BASIC DESIGN


HULL FORM USAGE
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

• Merchant Ship

• Naval & Coast Guard Vessel

• Recreational Vessel

• Utility Tugs

• Research & Environmental Ship

• Ferries
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

DFP IN BASIC DESIGN


HULL FORM BY SUPPORT
TYPE
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

• Aerostatic Support
- ACV (Air Cushion Vehicles)
- SES (Captured Air Bubble)
• Hydrodynamic Support
- Hydrofoil
- HYSWAS (HYdrodynamic Small Waterplane
Area Ship)
-Planning Hull
• Hydrostatic Support
- Conventional Ship
- Catamaran
- SWATH (Small Waterplane Area Twin Hull)
- Deep Displacement
• Submarine
- Submarine
- AUV/ROV
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Aerostatic Support
- Supported by cushion of air generated by a
fan.
- ACV (Air Cushion Vehicle)
hull material : rubber
propeller : placed on the deck
amphibious operation
- SES (Surface Effect Ship)
side hull : rigid wall(steel or FRP)
bow : skirt
propulsion system : water jet propulsion,
supercavitating propeller, not amphibious
operation
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Aerostatic Support
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Aerostatic Support

E
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Aerostatic Support
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal
Hydrodynamic Support
Planning Hull
- supported by the hydrodynamic pressure developed
under the hull at high speed
- V or flat type shape
- commonly used in pleasure boat, patrol boat,
missile boat, racing boat
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal
Hydrodynamic Support
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal
Hydrodynamic Support
Hydrofoil Ship
- supported by a hydrofoil, like wing on an
aircraft
- fully submerged hydrofoil ship
- surface piercing hydrofoil ship
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal
Hydrodynamic Support
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal
Hydrodynamic Support
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal
Hydrodynamic Support
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal
Hydrostatic Support
• Displacement ship
- conventional type of ship
- carries high payload
- low speed
• SWATH
- small waterplane area twin hull (SWATH)
- low wave-making resistance
- excellent roll stability
- large open deck
- disadvantage : deep draft and cost
• Catamaran/Trimaran
- twin hull
- other characteristics are similar to SWATH
• Submarine
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal
Hydrostatic Support
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal
Hydrostatic Support
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal
Hydrostatic Support
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal
Hydrostatic Support
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal
Hydrostatic Support
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal
Hydrostatic Support
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal
Hydrostatic Support
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal
Hydrostatic Support
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

DFP IN BASIC DESIGN


HULL FORM DEVELOPMENT
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

The Design Spiral


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Ship Hull Form and Geometry

• Since the ship is a 3-dimensional shape, data


in x, y and z directions is necessary to
represent the ship hull.
•Table of Offsets
•Lines
- body plan (front View)
- shear plan (side view)
- half breadth plan (top view)
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Ship Hull Form and Geometry

Figure 2.2 - The Projection of Lines onto 3 Orthogonal Planes


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Ship Hull Form and Geometry


Intersection of planes (waterlines) parallel to the
baseline (keel).

Figure 2.3 - The Half-Breadth Plan


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Ship Hull Form and Geometry


Intersection of planes (buttock lines) parallel to the
centerline plane

Figure 2.4 - The Sheer Plan


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Ship Hull Form and Geometry


Intersection of planes to define section line
Sectional lines show the true shape of the hull
form
Forward sections from amidships : R.H.S.
Aft sections from amid ship : L.H.S.
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Ship Hull Form and Geometry


SHIP SURFACE FAIRING
• Maximize parallel body
• Maximize flat of bottom and flat of side
• Use a straight line stem profile
• Use a flat vertical transom
• Make sure the forefoot shape has fair frame lines
• Select a bilge radius so that one plate width can
handle bilge strake
• Eliminate shape that forces decision to use
castings in the stem and stern
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Ship Hull Form and Geometry


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Ship Hull Form and Geometry


EconoForm: Entirely flat or conical surfaces, patented in 1999
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Ship Hull Form and Geometry

Fishing vessel Tug


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Ship Hull Form and Geometry


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

DESIGN/PRODUCTION
INTERFACES
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Design/Production Interfaces
• Implementation of the Build Strategy in order to:

Prepare a design that takes into account agreed


processes, facilities and equipment

design out non-value work

ensure integration of steel and outfit work to give


shortest delivery schedule

increase STANDARDIZATION
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Design/Production Interfaces (Continued)


• Definition of processes and standards to allow simple of
effective planning systems to be used.
• Development of Interim Product System
• Production simplification
• Definition of optimum methods based on existing
facilities and equipment to maximize flowline production
• Identification of facility and equipment changes that will
improve productivity
• Communication of change to technical and planning
functions
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Design/Production Integration (Continued)


These can be seen in the following current shipbuilding
practices:
 Use of 3D product model as design/ production integrator,
 Product-oriented Work Breakdown Structures (PWBS),
 Intermediate product catalogs/databases,
 Development of Shipbuilding Policies,
 Use of Build Strategies,
 Preparation of engineering as workstation information
packages,
 Use of Concurrent Engineering and associated teams to
ensure design/production engineering, and
 The use of design build plans by the most recent
design/planning
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Engineering for Ship Production


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Engineering for Ship Production (Cont.)


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Engineering for Ship Production (Cont.)


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Engineering for Ship Production (Cont.)


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Engineering for Ship Production (Cont.)


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Engineering
for Ship
Production
(Continued)
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Engineering
for Ship
Production
(Continued)
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Engineering for Ship Production (Cont.)


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Engineering for Ship Production (Cont.)


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Engineering
for Ship
Production
(Continued)
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Engineering
for Ship
Production
(Continued)
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Engineering for Ship Production (Cont.)


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Engineering for Ship Production (Cont.)


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Engineering for Ship Production (Cont.)


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Engineering
for Ship
Production
(Continued)
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Engineering for Ship Production (Cont.)

Vosper Thornycroft

BAE Marine Barrow


BAE Marine Govan

BLOCK A MEGA-BLOCK B + C BLOCK D BLOCK E BLOCK F

UK MOD TYPE 45 SHIP GRAND BLOCK BREAKDOWN


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

UK MOD TYPE 45 SHIP BOW GRAND BLOCK


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

UK MOD TYPE 45 SHIP BOW GRAND BLOCK


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

UK MOD TYPE 45 BOW SECTION DESTROYER


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

UK MOD TYPE 45 MID BODY DESTROYER


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

COMPLETED UK TYPE 45 DESTROYER


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

SPANISH FRIGATE BLOCK BREAKDOWN

Spanish Built Norwegian Frigate Block Breakdown


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

NAVAL SHIP ON-BLOCK OUTFITTING


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

NAVAL SHIP ON-BLOCK OUTFITTING


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

B&V Construction inside a Covered Floating Dry-


dock
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

SHIPBUILDING PROCESS
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

SHIPBUILDING PROCESSES

• The shipbuilding process consists of fabricating raw


material into ship parts and assembling them, along
with purchased equipment and components (interim
products) to produce the finished product, namely the
ship.

• All shipyards have the same basic processes.


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

SHIPBUILDING PROCESSES
NON-CONSTRUCTION CONTRUCTION
Administering Storing
Managing Handling
Marketing Preparing
Designing Cutting
Estimating Fabricating
Contracting Welding
Engineering Assembling
Planning Block Constructing
Ordering/Buying Block Outfitting & Painting
Managing Material Block Erecting
Delivering Zone Outfitting
Guaranteeing Launching
Testing
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

SHIPYARD PROCESSES (Continued)


• Processing Equipment Structure
Blast & Prime
Cut and Mark
Plate Forming
Shape Forming
Panel Line
Assembly Line
Block Line
Curved Block Assembly
• Processing Equipment Pipe
Cutting
Flanging
Bending
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Structural Plate Parts


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Pipe Pieces
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Structural Profiles
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Hull Fitting Parts


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Slot Web Frame System


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Split Double Bottom Block Line


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Subassembly Pallets
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Block Outfitting
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Grand Block Assembly


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Curved Block Line


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Large Block being Outfitted


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Block Assembly Jig


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Outfitted Block Being Erected in Building Dock


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Grand Block Being Outfitted


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Grand Block Assembly


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Grand Block Assembly


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Grand Block Assembly


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Modern Covered Inclined Building Berth


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Building Dock
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Elevator for Mega Block Movement to Building Dock


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

A Very Heavy Lift Movement (14000 t)


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Subcontracted Blocks (Some Outfitted) delivered on Barge


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Subcontracted Blocks (Some Outfitted) delivered on Barge


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

ZONE OUTFITTING
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

ZONE CONSTRUCTION
• Zone Construction is a management methodology based
on organizing work by Zone rather than by System.

• Zone Construction relies as much on who does the


planning, scheduling and control, as the actual tools and
techniques for organizing the work.

• The intent of breaking the ship down into Zones is to


reduce the management tasks in size by being “Product-
oriented” rather than System-oriented.

• Zone construction may or may not use Advanced


Outfitting.
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

ZONE CONSTRUCTION (Continued)


The benefits of Zone Outfitting are:
• Reduced Work Package size and scope, by focusing
on Zones rather that the ship or large portions of it.
• This results in a level that an individual is more
capable of understanding and managing.
• Forcing all departments to pay attention to the
planning and interfaces in which they are involved.
• Forcing Production to take an active role early in the
product development.
• Promoting the use of multi-skilled teams.
• Engineering provides technical documentation that
supports Zone Outfitting.
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

ADVANCED OUTFITTING
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

ADVANCED OUTFITTING
• It is the fitting to ship structure, before and after it is
erected on the building berth, of outfit items at a
significantly earlier time in the building sequence than is
traditional.
• The organization of information and materials to a plan
that applies labor and facilities to integrate ship’s structure
and outfit materials at the earliest and most cost effective
stage of the construction process.
• Advanced Outfitting is normally divided into three types,
namely: On Unit On Block On Board
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

ADVANCED OUTFITTING (Continued)


GOALS
• Minimize on board outfitting
• Reduce outfitting time thus total building time
• Simplify outfit planning
• Avoid interference between trades
• Improve material handling
• Improved use of cranes
• Improved quality, productivity and worker safety
BENEFITS
• Reduced/eliminated overhead work
• Improved access, (workers and material) ventilation and
lighting
• Reduced/eliminated scaffolding
• Reduced/eliminated on board services
• Improved tool/equipment availability
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

On-block Advanced Outfitting


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

On-block Advanced Outfitting


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

On-block Advanced Outfitting


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Finish On-block Advanced Outfitting


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Finish On-block Advanced Outfitting


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Modular cabin Advanced Outfitting


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Multilevel On-unit Advanced Outfitting


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

LAUNCHING METHODS
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

End Inclined Sliding Launch


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

End Inclined Sliding Launch


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Launching Ways and Cribbing


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Rotating Fore Poppet


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Stern Cribbing and Shoring


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Center Ground Way with Teflon Strips


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Center Way Crushing Strip Fore Poppet


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Side Launching
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Side launching Excitement


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

To Have a Canal –> Will Build ships


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Ship In Floating Dock Prior to Launch


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Ingalls Launching Sequence


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Submersible Barge Launching System


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Getting the Foot out of the Shoe – Launching from Building Dock
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Building Ledge and Dry-dock


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Multiple Repair Ledges for Overflooding


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

SHIPYARD EQUIPMENT
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Plates Leaving Blast and Prime Machine


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Material Handling – Automated Guided Vehicle (AGV)


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Plasma Cutting and Marking Machine


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Laser Cutting and Marking Machine


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Automated Milling Machine – Two plates at a time


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Panel Line
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Laser Welding Panel Line


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Laser Welding Panel Line


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Two Large Panel Lines


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Special Panel Turnover Device for Two-sided Welding


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Material Handling – Profile Magazine – pre-processing


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Material Handling – Profile Magazine – post-processing


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Robotic Profile Cutting and Marking Line with Conveyors


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Material Handling and Robotic Arm for Profile Cutting


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Same Robotic Arm used for Welding and Cutting


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Semi Automatic Stiffener Fit and Tack Weld Station


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Robotic Sub Assembly Line


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Long Plate Butt and Girder Fillet Laser Welding Machine


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Robotic Double Bottom Welding Machine


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Robotic Material Handling for Robotic Tack Welding Machine


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Robotic Stiffener Handling and Tack Welding


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Robotic Welding Subassembly Line


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Robotic Double Hull Welding Workstation


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Robotic Double Hull Welding Line


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Robotic Double Hull Welding Machine


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Robotic Welding Machine Working with Curved Panels


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Rolls for Shaping Plate with Single or Minimum Double Curvature


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Ring Press for Shaping Plate with Double Curvature


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Hydraulic CNC Frame Bender


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Plate Shaping by Line-heating


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Early Tilt Table for Welding Curved Plate Panels


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Moving Curved Block Line – Pin Jigs on Platforms


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Modern (In Line) Tilt Table for Welding Curved Plate Panels
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Modern (In Line) Tilt Table for Welding Curved Plate Panels
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Pipe Stowage Magazine – pre processing


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Pipe Bending Machine


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Material Handling Automation – Conveyor Systems


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Material Handling Building Dock gantry/Goliath Cranes


SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal

Grand Block Elevator


THANKS
SHIP CONSTRUCTION, KEY NOTES FOR THIS FASCINATING PROCESS
Roberto Morante Villareal
Marine Engineer & Naval Architect
MARINE STRUCTURES & MATERIALS DEPARTMENT MANAGER
rmorante@cotecmar.com
roberto.omar.morante.villareal@gmail.com