1.

0 Introduction

An ideal layout for a modern shipyard is based on a production flow basis, with the
yard extending back from the river or shore at which the berths or building dock are located.
The furthest area from the berths is reserved for the material stockyard, and between the two
are arranged in sequence the consecutive work and shop processes. Too often existing
shipyards follow the river bank, and are restricted by their location in a built up area or the
physical river bank slope from extending back from the river, so that modified production
flow lines are required.

2.0 Literature Review

Planning a new shipyard, or re-planning an existing one, will involve decisions to be

made on the following:

 Size and type of ship to be built.

 Material production per year to be achieved.
 Material handling equipment to be supplied.
 Machining processes to be installed.
 Unit size and weight to be fabricated and erected.
 Amount of outfit and engine installation to be undertaken.
 Control services to be supplied.
 Administration facilities required.

Shipyards usually have a fitting out basin or berth where the virtually completed ship
is tied up after launching and the finishing off work and static trails may be carried out.

Before considering the actual layout of the shipyard it is as well to consider the
relationship of the work processes involved in building a ship as illustrated in Figure 1.0.

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 Figure 1: Shipbuilding process

An idealized layout of a new shipyard is indicated in Figure 2 which might be

appropriate for a smaller yard specializing in one or two standard type ships with a fairly high
throughput so that one covered building dock or berth was sufficient.

Building docks can be of advantage in the building of large vessels where launching
costs are high, and there is a possibility of structural damage owing to the large stresses
imposed by a conventional launch. They also give good crane clearance for positioning units.
The greatest disadvantage of the building dock is its high initial cost.

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 Figure2: Atlantica Sul 3D Shipyard layout

Atlântico Sul Shipyard has the capability to process 160 thousand tons of steel per
year. It covers an area of 1.62 million m², including a sheltered industrial area of 130
thousand m², and a 400 m long x 73 m wide x 12 m deep dry dock. Its facilities include two
Goliath Gantry Cranes of 1.500 tons each, two cranes of 50 tons each and two other cranes of
35 tons each.

The scale of such plant facilities allows for a substantial reduction in the building
times and places our yard in the distinct group of Fourth-Generation shipyard, on the same
level as the Asian plants, which stand today at the forefront of the worldwide shipbuilding
industry.

The wharf area of Atlântico Sul Shipyard has a 730 m long Outfitting Quay, equipped
with two cranes of 35 tons each. An additional 680 m long Quay area is dedicated for usage
in the construction and repair of offshore platforms.

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3.0 Comparison between other shipyards by SWOT analysis

Figure 3: Richmond Shipyard Layout

1. FACILITIES

 Slipway
 Construction bays at the side of the slipway
 Outfitting jetty
 Sufficient skids for pre-fabrication of modules or panels.
 Well equipped workshop.

2. INFERENCE

 Shipyard specialized in smaller vessel especially those used in water ways and
for fishing.
 Capacity is limited.
 Delivery time is utmost important to get more orders and to maintain
credibilty
 Will need more facilities if wants to extends the productions.

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3.1 SWOT analysis of Atlantico Sul shipyard

 Strengths

o Located near Suape Industrial Complex

o Has construction facilities for Petrobras oil exploration-related vessels

o Has a facility solely dedicated to offshore rig construction and repair

 Opportunities

o Uses Samsung Heavy Industries construction technology because of

technology transfers

o Can be used for construction of oil exploration vessels and facilities

3.2 SWOT analysis of Richmond shipyard

STRENGTHS WEAKNESSES

1. Short communication line within 1. Being a private. No government

workers support
2. Implement modern management 2. Highly cost of maintenance of the
approach equipment
3. Highly train and skilled workers 3. High financial reserve
4. Modern and high technology
equipment
5. Minimum delivery time
6. High credit ratings

OPPORTUNITIES THREATS

1. Good financial that help economy 1. Strong competition

2. More returning orders 2. Higher corporate tax
3. Good law and policies 3. Higher charges from supplier

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4.0 Conclusion

From the investigation it emerged that the implementation of Group Technology

concepts profoundly modified the work organisation within shipyards as it shaped their
respective layouts. Its generalisation was motivated by the need to reduce production costs
whilst maximising the resources utilisation.

Production lines were developed for fabrication and preparation of shapes and plates,
and for stiffened plate or panels. Flow lines and work stations were established for fabrication
of steel hull assemblies and installation of their outfit. Even the erection of the assemblies
was specified at certain locations in a repetitive sequence, and meets the criteria of a
production line process. Further, production lines are considered to be practical for
preparation of outfit, such as piping, ventilation ducts, heads, electrical cable harnesses,
ventilation machinery rooms, foundations, and similar items.

The shipyard mechanical and electrical equipment requirements were derived from a
cursory analysis of the jobs to be done, and production equipment was then located at each
station of the many production lines. The use of jigs and special tooling to expedite repetitive
manufacture of similar products was specified for most production lines. The possibilities of
automating many steps in the production lines are apparent, much more so than in
conventional shipbuilding,

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5.0 References

 http://www.estaleiroatlanticosul.com.br/eas/en/home/section/technological_characteri
stics.htm
 CONCEPTUAL DESIGN OF A MECHANIZED SHIPYARD FOR FAST
DEPLOYMENT LOGISTICS(X) PRODUCTION - Benjamin V. Andrews
 MALAYSIA’S SHIPBUILDING INDUSTRY – SHIFTING TOWARD
SUSTAINABILITY - Anuar Mohd Noor ,Principal Analyst ,Industry Intelligence & Foresight
 Design of a Small Shipyard Facility Layout Optimised for Production and Repair -
Hamid CHABANE, Commandement des Forces Navales