About Shipyard Layout

MODERN SHIPBUILDING PRACTICE
SHIP PRODUCTION HISTORY

A 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
Relatively low investment cost
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SHIP PRODUCTION HISTORY (Continued)

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
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BRIEF CHRONOLOGY OF SHIPBUILDING TECHNOLOGY

DEVELOPMENT
The civilizations and countries which have been linked to the development of
shipbuilding technology are:
Crete
10000 to 4000 BC
Egypt
5000 to 2100 BC
Egypt
2100 to 600 BC
Phoenicia1500 to 331 BC
Carthage 800 to 241 BC
Greece
700 to 146 BC
Rome
270 BC to 420 Ad
Venice 420 to 1500 AD
Genoa 640 to 1500 AD
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Mediterranean seagoing for trade

Nile river warships
Mediterranean seagoing warships
Mediterranean seagoing for trade
Mediterranean, Europe and Africa for trade
Mediterranean trade and warships
Mediterranean, Europe and Africa warships
Mediterranean and Europe trade with
warships for protection
Same as Venice
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BRIEF CHRONOLOGY OF SHIPBUILDING TECHNOLOGY

DEVELOPMENT (Continued)
Vikings 900 BC to 1066 AD Ships for exploration and war
England 811 to 1850 AD
Wooden ships for war and trade
Hansa
1241 to 1660 AD Ships for trade
Spain
1500 to 1600 AD Ships for exploration
France 1500 to 1900 AD Ships for war
USA
1776 to 1875 AD Sailing ships and first clipper ships
Britain 1838 to 1950 AD Iron and steel hulled steamships
USA
1916 to 1919 AD World War I emergency fleet
USA
1940 to 1945 AD World War II emergency fleet
Germany 1945 to 1955 AD Diesel motor ships
Denmark 1945 to 1960 AD Diesel motor ships
Japan
1958 to Present
Development of large shipbuilding
Korea
1973 to Present
National program to become worlds biggest
shipbuilding country.
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SHIPBUILDING
Iron and steel ship construction methods basically followed
the way wooden ships were built That is, the keel was laid,
stem and stern posts erected, frames erected, deck beams
erected, plating applied to shell and decks.
The ship was launched as soon as possible, without much
outfit and machinery installed, towed to an outfitting pier
where the engine would be installed and the ship completed.
Welding enabled a major change in the way ships were built.
Welded sub-assemblies were constructed and assembled into
panels and double bottoms in the fab shops and then erected
on the berth. This approach was called pre-fabrication and
the outfit that was installed in the assemblies, pre-outfitting.
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SHIPBUILDING (Continued)
With the increase in the size of ships, the pre-fabrication and
pre-outfitting approach was further improved and the block
construction and advanced outfitting approach was developed
The final step in the development was Zone Outfitting
Current improvements are in the areas of CAD/CAM/CIM
implementation automation of structural and pipe fabrication
and robotics in many shipbuilding applications
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World shipbuilding market cycles
M GRT (LOG SCALE)
35.0
Launches
14.0
3.0
1.0
1893 1903 1913 1923 1933 1943 1953 1963 1973 1983
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Year
Merchant Ships Completed
Million GRT
50
40
30
20
10
0
1960
1965
1970
1975
1980
1985
1990
Year
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Target Market Volumes

Ship Type
Bulk Carrier
General Cargo
Tanker
Container
Passenger (including Ferries)
Chemical Tanker
RoRo
Reefer
OBO
LPG
LNG
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Relative Market Volume

62.3
53.3
31.5
21.6
17.4
17.1
13.9
12.8
1.3
5.0
1.0
12
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SHIP REPAIR
Ship repair is greatly impacted by environmental concerns:
blasting lead paint from hulls
painting/overspray
removing asbestos and other insulation
Topside repairs can be done anywhere with the ship in the

water
Bottom repairs can only be done either by:
trimming the ship if repairs are at the ends
beaching and heeling the ship
landing on tidal grid
marine railway
graven dock
floating dock
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SHIP REPAIR (Continued)

Types of repair include:
Voyage repair - for damage breakdown sustained during
operations. May or may not require ship pulled from
service
Class repair - every 4 to 5 years in conjunction with class
survey
Upgrade/modifications
Conversion
Repairs are done everywhere around the world in convenient
locations - major ports and on trade routes
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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
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SHIPYARD LAYOUT AND EQUIPMENT

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.
Shipyards should be close to and have access to the open sea,
and road and/or rail system should be suitable for delivery of
equipment, components and raw materials.
Shipyards should also be located where there is adequate
educated and trained people.
At least one boundary should be adjacent to the water.
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SHIPYARD LAYOUT AND EQUIPMENT (Continued)

Shipyards require the following attributes:
Warehouses and raw materiel storage areas.
Shops to fabricate and assemble parts into subassemblies, assemblies and even outfitted blocks.
Building berth and system of transferring ship to water
- launchway, drydock, floating dock.
Pier(s) to secure the ship after launch.
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Goals of facility layout that must be considered are:
Optimizing material and work-in-process inventory
minimizing buffer storage consistent with uniform
flow through-out the yard.
Minimizing the number of lifts and reducing the
Distance material and interim products must be
transferred.
Block Construction and Advanced Outfitting require greater
lift capacity cranes. 200T Whirleys and 1000 T+ Gantrys.
Most U.S. shipyards have been in existence for many years
and are constrained by existing plant boundaries and layout.
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Material Handling
Conveyors
Cranes
Transporters
Elevators
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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
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About Shipyard Layout

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About Shipyard Layout

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MODERN SHIPBUILDING PRACTICE

SHIP PRODUCTION HISTORY

MODERN SHIPBUILDING PRACTICE

SHIP PRODUCTION HISTORY (Continued)

MODERN SHIPBUILDING PRACTICE

BRIEF CHRONOLOGY OF SHIPBUILDING TECHNOLOGY

Mediterranean seagoing for trade

MODERN SHIPBUILDING PRACTICE

BRIEF CHRONOLOGY OF SHIPBUILDING TECHNOLOGY

MODERN SHIPBUILDING PRACTICE

MODERN SHIPBUILDING PRACTICE

MODERN SHIPBUILDING PRACTICE

World shipbuilding market cycles

M GRT (LOG SCALE)

MODERN SHIPBUILDING PRACTICE

Merchant Ships Completed

MODERN SHIPBUILDING PRACTICE

Target Market Volumes

Relative Market Volume

MODERN SHIPBUILDING PRACTICE

Topside repairs can be done anywhere with the ship in the

MODERN SHIPBUILDING PRACTICE

SHIP REPAIR (Continued)

MODERN SHIPBUILDING PRACTICE

MODERN SHIPBUILDING PRACTICE

SHIPYARD LAYOUT AND EQUIPMENT

MODERN SHIPBUILDING PRACTICE

SHIPYARD LAYOUT AND EQUIPMENT (Continued)

MODERN SHIPBUILDING PRACTICE

SHIPYARD LAYOUT AND EQUIPMENT (Continued)

MODERN SHIPBUILDING PRACTICE

SHIPYARD LAYOUT AND EQUIPMENT (Continued)

MODERN SHIPBUILDING PRACTICE

SHIPYARD LAYOUT AND EQUIPMENT (Continued)

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