NAME : LINGGESWARAN A/L JAGANATHAN

ID NO : 56280113134
SUBJECT : SHIPYARD MANAGEMENT AND PROJECT PLANNING.
TOPIC : INDIVIDUAL ASSIGNMENT
SUBJECT CODE : LGB 20303.
LECTURER NAME : EN. AZIZ ABDULLAH

Table of content.

Introduction.. 1

The layout and other problems in shipyard.. 2

The shipyard layout. 5

The improvement plans... 6

Berthing and docking arrangements. 9

The material flow within the upgraded shipyard 19

Conclusion... 21

Recommendations... 22

References 23

Introduction.
An ideal layout of 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 docks are located. The
farthest area from the berths is reserved for the material stockyard and between the two is
arranged in sequence the consecutive work and shop processes. Too often existing shipyards
follow the river bank and are constrained by their location in a built up area or the physical river
bank slope from extending back from the river. Therefore, modified production flow lines are
required.
Plan for the shipyard will involve decisions to be made from the following:

Size and type of the 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 outfits and engine installation to be undertaken
Control services to be supplied
Administration facilities required

The Layout and Others Problems in Shipyard

1. The space for arranging the building blocks of ship which is under construction.
The major problem that affects the safety and smooth workflow on shipyard is
because of paucity of space for arranging the building blocks of ship under construction.
Therefore, a standardized erection sequence diagram is generally available to provide the
prioritized erection sequence and it serves as the frame work. In order to make a timely
erection of the blocks a post plan has to be developed, so that the blocks lie in the nearest
possible vicinity of the material handling devices while keeping the priority of erection
and the blocks are arranged in the pre-erection area. This kind of readiness of blocks
leads to a very complex problem of space. This arises due to the least available space
leading to an urgent need for intelligent spatial schedule without compromising the rate
of production.
There exists two critical problems ahead namely, the spatial occupation layout of
pre-erection area and the evacuating pattern in the spatial vicinity. The block shape is
assumed be rectangular. The related input data's are the dates of erection (earliest as well
as the latest), geometrical parameters of block available on pre-erection area, slack time
and the like. World over industrial engineers and decision makers are brainstorming hard
to find an ideal solution for their unique problems. Every scheduling and decisional
problems end up in complicated iterative loop system.

2. Working Condition
Shipyard workers working locations are categorized as one of the most risky
working surroundings. This not only adds the problems to their job but actually makes it
a work profile full of need for constant caution. Shipyards are not one of the most

comfortable places to work in because there is a constant danger in everything they does
and also hazardous to their health. There are several precautions that need to be taking in
count.
Sometimes it is extremely dangerous to work in cramped space while at other
times. As an example, due to fewer places to stand and work one misstep from the high
place can cause serious injury or even death. The cramped spaces (enclosed spaces) are
one of the riskiest places to be working in. A shipyard worker, while working in such tiny
spaces is often at risk of physical injuries to limbs, head or other body parts along with
more serious troubles like suffocation, asphyxiation etc. Extreme nature of working
conditions of shipyard workers is the first problem they face. Also, the high pressure in
such tiny spaces can often cause much more grave and permanent damage like eardrum
rupture. Shipyard workers often complain of problems to their hearing abilities due to
working constantly under high pressure conditions.
Besides that, working in shipyards are not as the same as one working in office
where they can go back on time. There are no fixed timings. The extreme nature of their
job means the workers have to be available at all times. The unpredictable time schedules
make this job harder than it already is, and definitely adds to the woes of workers.
Sometimes they even have to work for several hours together without much rest.

3. Machinery and Material Hazard

Shipyards are the places where work happens at a big scale. The machinery used
is huge, often requiring immense skill and strength to be handled. A minor divergence
while working at such machinery can corroborate to be extremely fatal for any shipyard
worker. The seriousness of injury can be as loss of life. In some cases, records of workers
having been gravely injured date back to as early as 1940s, where ship construction

really took off all over the world. Constant danger posed by the heavy machinery is what
is third problem faced by shipyard workers.
Asbestos is used as one of the construction materials for most ships even till
today. Shipyard workers involved in work of manufacturing of ships and even those not
specifically into that particular aspect of shipyard jobs often receive extremely high
exposure to asbestos, making them quite vulnerable to diseases caused by it. Asbestosis,
along with mesothelioma which can cause cancer caused exclusively by asbestos
exposure are very serious diseases found mostly in workers working in close proximity to
this substance. It is one of the biggest problems faced by workers working in the ship
industry especially so since there is still no perfect solution to this problem.
One of the bigger problems with this particular aspect of job is that the symptoms
caused due to exposure to asbestos can surface even after many years. Reports of these
symptoms showing up in a person up to 50 years after exposure to it have been found.
This adds a whole new dimension to this problem making it much more serious.

The Shipyard Layout

A perfect layout of this shipyard is indicated in Figure.1 which might be appropriate for a
small yard specializing in one or two standard type of ships with a fairy high throughput so that
one covered building dock or berth was sufficient. At this point, it may be convenient to mention
the advantages and disadvantages of building docks as opposed to building berths. Building
docks can be advantage in the building 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.

The yard also gives good crane clearance for positioning units. The greatest disadvantage of the
building dock is its high initial cost.
Many yard reconstructions and upgraded have incorporated undercover construction
facilities in the form of docks or slipways within the building halls. Others have building halls at
the head of the slipway with advanced transfer systems installed so that the hull can be extruded
out of the hall onto the slipway for launching. Such facilities permit ship construction in a
factory type environment providing protection from the worst effects of weather and darkness.
The shipyard in this case is located on the area of 13.2 hectares and in addition
encompasses 2.5 hectares of water surface area with the depth of 4 meters. This allows the access
of river-sea vessels of no more than 10,000 DWT with empty ballast. Major shipyard equipment
includes:

751 m of mooring lines equipped with compressed air lines, water supply, power

supply as well as berth cranes with capacities of 10, 20 and 25 tones

Floating dock allowing to perform the repair of vessel underwater parts with docking

weight 2,000 t, length 115 m, width 16 m and draft 5 m;

The slipway allowing repairs of vessels with weight up to 1,000 tones and length up
to 70 m.

The current arrangement of the shipyard allows simultaneous repair works for 4-5 vessels
of above 100 m length, on the shipyards land territory and a float.

The Improvement Plans.

The shipyard should have the effective layout to ensure a smooth flow of work, material,
and information through the system. The requirements for effective layout such as:

Minimize material handling costs

Utilize space efficiently
Utilize labor efficiently
Eliminate bottlenecks

Facilitate communication and interaction between workers, between workers and their

supervisors, or between workers and customers

Reduce manufacturing cycle time and customer service time
Eliminate wasted or redundant movement
Facilitate the entry, exit, and placement of material, products, and people
Incorporate safety and security measures
Promote product and service quality
Encourage proper maintenance activities
Provide a visual control of operations or activities
Provide flexibility to adapt to changing conditions

This type of shipyard is known as the process layout where it is a group of similar
activities together in departments of work centers according to this process or function is that
they perform characteristic of operations that serve different customers different needs. This is
the most common layout for a small or medium size of manufactures. This typical process layout
would group lathes in one area, drills in one area, milling machines in one area and so on which
shown in Figure 1.

Figure 1: Shipyard Layout

In order to stay competitive in the increasingly demanding commercial, military, leisure

markets, and shipyard must continuously improve their overall performance and productivity.
Their approach to shipyard design and development to ensure that the facilities, processes and

practices will allow the yard to achieve the level of performance required for market success.
They use the same tools to analyze the existing yards and to assist them develop effective
performance improvement programs. This shipyard is internationally acclaimed the shipyard
benchmarking system that are allows the processes and practices employed in shipbuilding, ship
repair and naval vessel support to be quickly analyzed, compared to international best practice
and the performance improvement priorities identified. But still, the efficient analysis is just the
beginning for this shipyard is improved.
Eventually, the experts will assist their customers develop every aspect of the
performance improvement program and then, it will transfer the necessary technology and, if
required, to provide the training and operational assistance to this shipyard. They can also help to
find experienced people to join their team for full time. They place the particular emphasis on
optimizing the strategy and approach prior to recommending expenditure on expensive facilities
and equipment. The shipyard service includes:

Cost structure review, financial analysis and business strategy development

Industry benchmarking and technology profiling
Operational benchmarking and identification of technology gaps
Development and implementation of performance improvement programs
Implementation of modern shipbuilding and repair technology
Management and staff retraining program

Moreover, the shipyards location is the important reasons why this shipyard is more
competitive than the others shipyard in term of delivering the long term economic viability of the
shipyard business. It also make shipyard layout is the best layout which can access to markets,
accessibility for shipping, and depth of surrounding waters, suitability of land surface and the
marine environment are all factors to be considered and are crucial to the success of your
shipyard development project. When they are in the process of explore and choose the location
for the shipyard, they were follow some selection criteria such as shipping traffic pattern
analysis, topographic, bathymetric and ground studies, the environment impact as well as the
ancillary industry and the labor availability.
Therefore, the competitiveness that has been study by this shipyard has established the
correlation between the use of best practice, output performance and profitability. To achieve the

desired performance, a shipyard must be correctly configured and employ appropriate processes
and practices for its product mix and cost base. Most importantly the shipyards benchmarking
system, the best layout and the cost structures as well as the capacity models determine the
overall characteristics of new and redeveloped shipyards. Likes this shipyard which they used to
specify the processes and practices required achieving market success through optimizing the
facilities, the production technology and in particular the pre-production technologies employed.

Berthing and Docking Arrangements

Berthing arrangement refer to a place where a ship needs to tie up at alongside a wharf or
a pier structure. With regards to a shipyard, a berth is a place where a ship is moored within a
shipyards perimeter before or after down-slipping and usually the ship is meant to undergo pre
or post slipping works that cannot be done in the docks or on the slipway or further outfitting
works after launching while afloat. While berthed in the shipyard, works that require lifting
operations are usually provided for shipside cranes and ship may be pulled conveniently to other
nearby outfitting berths if required.
Large ships are usually launched down a slipway or flooded up in a dock where they are
built. In the case of a shipyard with a building dock the large hull blocks that comprise the ship
are assembled on a level line of building blocks which are similar to docking blocks. Building
docks tend to be shallower than graving docks as the ship is flooded up considerably lighter than
the lightship condition. Usually, the building dock has concrete ramps built into the head end of
the dock to allow for the construction of more than one vessel at the same time. A docking plan
must be made by the ship owner to a dock master to enable him to plan the necessary docking
arrangement with regards to correct placement of keel blocks and bilge blocks to avoid placing
them at the wrong places.

Mooring lines - is a thick rope or cable which is used to tie a watercraft in place. Usually
multiple mooring lines are used on the same vessel to distribute the stress, and to act as
redundant systems in case a mooring line snaps. Mooring lines may also be known as
hawsers. A number of materials can be used to make a mooring line, and most marine
supply companies carry an assortment of options which can be customized as needed.
Mooring a vessel requires some coordination.

Figure 2: Mooring Lines

The mooring lines need to be thrown to shore, but they are sometimes too heavy and
awkward to be thrown easily, especially in the case of lines used on large ships. As a
result, sailors use an attachment called a heaving line, a lightweight cord which can be
tossed to shore. People on shore can use the heaving line to pull the mooring line over so
that the boat can be moored in place. With a very large ship, a large crew on land may be
involved to coordinate the mooring process. For smaller craft, a single sailor can handle
mooring independently.

Slipway will consists a ground way and a sliding way that support the cradle on which
the ship is to be launched. The slipway is constructed with concrete, wood, steel or the
combination of these all materials. Ground ways area is from the building space into the
water. They may be permanently left in place or removed and stored between launchings.

Figure 3: Slipway

Ground ways width is restricted by the width of the sliding ways where they are slightly
wider than sliding ways. Frequently, there are only two ground ways are used for
endways launches but it is possible to used more than two.

Sliding ways- is a structure on which the ship travels into the water. It is traditionally
made of timber where nowadays, the ways are made from steel. The bottom edge of the
sliding way and the top edge of the ground ways are usually lad in a slippery surface. A
slipway provides for an inclined building berth which it is inclined at an angle and the
launch way will facilitate either end launching or side launching operations.

End launching- takes space and occupies areas outside of the yard during the operation of
launching. The past thought that end launching was the only method of getting a ship into
the water has now given way to advantages of the level building dock and the flood up
method. There is the approximate number of inclination of the building berth that is
0.045-0.065 to 1.000. The vessel is initially constructed on curved body blocks and center
line blocks to hold the structure in place. As the structure grew, the keel block, bilge and

cribbing blocks were built around the vessel. Then, the vessel weight is transferred from
the center line blocks to the launching cradle. The cradle sides are designed to slide down
the launching ways into the water stern first and on the time of launching, the vessel
slides backwards down the slipway on the frame until it floats by itself.

Floating docks- are have the capability of being moved to many locations and are
considered by some to be greater value for money than graving docks. Floating docks are
really ships themselves. The structure that was usually made up by the steel is mainly a
set of floating tanks serviced by ballast lines to pump rooms. The floating docks is
moored and submerged in the water to permit ships to enter. It is also has the capability to
be brought to a vessel that is badly damaged and unseaworthy.

The dock can be maneuvered underneath ships and has the ability to change its own trim
to coincide with that of the ship to be docked. Most floating docks have workshop,
facilities and accommodation to allow full support for refit activities at the docks. The
dock has its own electric power system, making it entirely independent from shore supply
for all docking operations.

Figure 4: Floating Dock

Figure 5: Floating Dock

Fabrication workshop - is a dedicated area with an assortment of equipment to make

possible the creation of sheet metal and structural fabrications. It is the place where the
material will be cut, rolled, bend, pressed and others.

Figure 6: Fabrication Workshop

Stockyard- is the place where the materials received from external sources such as plates,
structural bars and other construction materials are kept before being conveyed or passed
on to the various working bays.

Figure 7: Stockyard

Construction Hall - situated adjacent to the ship-repair facilities and features direct river
access via a conventional slipway launch, or vehicular access for large modules to the dry
docks. The hall offers an un-rivaled under-cover building environment allowing large
steelwork units such as complete hulls or project specific modules to be constructed
without environmental interference as well as the various front and side loading fork lift
trucks.

Figure 8: Construction Hall

Welding Workshop is the place where cut parts are fabricated into sub-assemblies, all
types of welding such as MMAW (Manual Metal Arc Welding), GMAW (Gas Metal Arc
Welding) and GTAW (Gas Tungsten Arc Welding) are carried out automatically or
manually, sub-assemblies being formed into larger assemblies with compartments, piping
systems and conduits for cabling and larger assemblies being formed into block
assemblies or modules.

Figure 9: Welding

Warehouse- is a commercial building for storage of goods. Warehouses are used by

manufacturers, importers, exporters, wholesalers, transport businesses, customs, etc. They
are usually large plain buildings in industrial areas of cities and towns and villages. They
usually have loading docks to load and unload goods from trucks. Sometimes warehouses
are designed for the loading and unloading of goods directly from railways, airports, or
seaports. They often have cranes and forklifts for moving goods, which are usually placed
on ISO standard pallets loaded into pallet racks. Stored goods can include any raw
materials, packing materials, spare parts, components, or finished goods associated with
agriculture, manufacturing and production.

Figure 10: Warehouse

Main Office- is place that serves as the administrative center of an enterprise. This is
where the management and administration staff carries out their duties.

Security is to make sure that the shipyard materials and equipment are protected as well
as to ensure the safety of the staff and monitoring of people entering or leaving the
shipyard premises.

Yard Services is to ensure that the shipyard is operated smoothly such as the provision
of tug boat services, transportation of materials within the shipyard, all internal technical
needs such as electrical and mechanical services as well as the landscaping and cleaning
services.

Technical and Electrical Services is one of the support team on the technical matters for
example engineering, drawing office, planning and control. These people dont actually
build the ships but without them the ship cant be built.

The Material Flow within the Upgraded Shipyard

In shipbuilding, the ship is built to order and is usually one-off product. This requires
implementation of the unique procurement process for all the materials required and work flow
requirements in the shipyard during ship construction. The procurement materials or services for
the construction of ships may include the following:

raw materials such as ferrous and non-ferrous plates, bars, timbers and fiber glass
paints for underwater hull, superstructure and interior
sub-contract works such as installation of navigation equipment, tiling and

cabling
spares for ship equipment and ancillaries
special tools, equipment and related spares

Material flowing from the warehouse to the shops and ultimately the ship is shown in
Figure 11 below. In shipyards, there are holding places (usually open spaces) for material to be
used for work in progress (WIP). These places should be located to minimize travel distance and
time for delivery flow by locating them closest to the point of use locations. But this is not
always the case. Sometimes the holding places are located according the available space in the
shipyard. Production Control (PC) which also shown in Figure 11, prepares work packages and
orders the appropriate material required to complete the job and maintain even workloads
throughout the various workstations within the construction process.

They are help to determine where the material will go, whether immediately to the work
station, or to the holding places if craft is not ready to use it immediately. Many times the
material may sit in the holding places for long extended periods because the material was not
actually needed. And when it is needed, work must stop until that material is located, loaded up
and then brought to the workstation. The time it takes to perform this task is dependent on the
location of the holding place and its distance from the workstation or the ship. This of course

Causes a slip in the schedule for the work to be performed and time is money. Also if the
material is not taken straight to the workstations or ship, then the transportation (usually trucks,
possibly cranes) will have to make multiple trips and cost the shipyard additional money.

Figure 11: Basic Shipyard Material Flow Model

CONCLUSION
The range of services offered by the shipyard includes repairs as well as the construction
and modernization of vessels. Repair works for ships weighing up to 1,000 tones comprise of:

Arrangement of the defect finding and ship repair process,

Ships hull defects detection,
Replacement of shell plating areas with deck plating framing,

Defect finding and repair of shaft lines and propellers, ship systems piping, valves and

other fixtures, auxiliary machinery and ship electrical equipment,

Building-up welding and mechanical treatment,
Mounting and alignment of shaft lines on a vessel.

The shipyards capabilities allow the various types of vessels including sea-river and sea
going vessels (up to 115 m length), fishing vessels; dry cargo carriers and tankers used the
services offered in shipyard. There is also the benefit of a good layout which may include:

smooth material flow

reduced inventories
better scheduling
effective space utilization
fewer production bottlenecks
reduced material handling costs

RECOMMENDATIONS
The success of shipyard depends on the decisions that are made at the design stage. Their
capability includes the process design and the others necessary such as civil, structural,
mechanical and electrical systems design. Besides that, they also should have great infrastructure
facilities that may include dry docks including dock gates, ship lifts, floating docks, ship launch
systems, piers, quays, breakwaters, dredging, fabrication halls, and the offices.

The ultimate shipyard is design from a few people from different expertise which are
later combined. This will provide all detailed shipyard infrastructure design requirements,
improving performance and on how to reduce construction and maintenance costs. Prior than
that, their initial concept designs will help the customers to make informed decisions before
committing to the cost of final detailed facility design. The design concepts components in the
best shipyard are often interchangeable, which means that the customers can combine attributes
from two or more concepts to arrive at the concept of the customers choice.

REFERENCES

1.
2.
3.
4.
5.
6.

http://www.iieom.orghttp://www.maritime-rh.com/areas-of-expertise/benchmarking.htmlhttp://www.ingentaconnect.com/content/sname/jspd/2010/00000026/00000002/art00007http://www.slideshare.net/agnikhil/shipyard-layout-improvement
http://www.sasape.com/slipway-services/shipyard-layout.html
Shipyard management and project planning book 4 th Edition. Prepared by: En. Aziz
Abdullah