Shipyard layout can be divided into : a. Prior to Word War II
b. Word War II – 1960
c. 1960 – Present
SHIPYARD CLASSIFICATION
1.Prior to Word War II

Shop facilities : a. Steel
b. Pipe
c. Machine
d. etc

they are located near the shipways and outfitting piers.

Outfitting (Installation of power plant and auxiliary machinery) was accomplished for the most part after launch.\
Riveting was the major process employed for joining steel plates and parts
First generation shipyard were characterized by :
a.along
b.narrow layout
c.along the waterway





2.Word War II – 1960
Were characterized by :
a.adoption of pre-fabrication or weldment
b.high-technology steel cutting and welding
section of the ship were built in shops and transported to the shipways where there are erected.
Works area were defined but with some flexibility and more complex scheduling and planning were required.
Crane capacity was increased to accommodate the movement of larger weldments.
The ship way become assembly area
Accurate gas cutting and high capacity welding method were developed “fabrication shops increased signifinantly”


3.1960 – Present
Influenced by specialized ship type, larger ships, etc
Work station were clearly defined and fixed
Scheduling and planning → work station
When launching : 65% complete
Crew who specialize in particular system (at outfitting piers)
1967 : era of the supertanker → shipyard (capacity)
Cranes 200 ton, 600 tons, up to 1.600 tons
Heavy lift gantry cranes, jib cranes
the major advanced is the 1960s was in mold loft procedure
foruth generation
a.product oriented
b.incorporate the principle of group technology
c.new construction and ship repair department


SHIPYARD FACILITIES AND SITTING
Factor should be considered : a. analysis of potential market
b.market share
c.vendor
d.labor market
e.environmental requirements
f.energy cost
g.cost of land and its availability




analysis should be also considered urban factor :
a.proximity to open sea and protection from the sea
b.general transportation
c.technical school and university

a target shipyard capacity has been selected based market analysis.
Facilities and size must be synchronized and balanced of material and intern product
Goal of facilities layout : a. optimizing materials and work
b. minimalizing buffer storage

ideal : shop around the building dock in U shape (basic different from third generation and a yard fully applying group technology)
repair facility, third generation = x → FAILURE
graving dock : a. nearly unlimited size
b. during flooding, all materials and equipments must be moved
c. expensive

floating dock : mobile
materials handling : use large capacity gantry crane
warehousing facility : a. located adjacent to the shop which use the materials.
b. Play a primary role in executing the production schedule
production facility : a. mould loft and marking
b. cutting and edge preparation
c. blasting and painting
(most blasting operations are carried out in enclosed space)
pipe fabrication : the pipe can be assembled and welded
production service : a. utilities
b. people mover
c. small tool
d. consumable storage and staging
e. some yard have elevator / escalator at outfitting piers
utilities : electricity, potable water, sewer service, compressed air, Ar, O2, natural gas, → ideally routed underground
small tools : electrode, wire spools, etc



PROCESS LANES
Group technology ship building system are based on the organization of work, using a product oriented, etc.
Process lanes = categorization and separation of similar type of work → efficient production
Process lanes → planning, scheduling, material flow
Sub assembly
a.outfit process lanes
b.outfit parts are manufactured in shops (pipe, machine, steel metal, and electric shop)
process lanes is far from the optimal U shape (fourth generation)
the detail of exiting facilities must be taken in to work location
the establishment of workstation productivity indices is essential for the planning, scheduling, and control of works load at process line.
Key to successful group technology are :
coordinating planning, scheduling design, and material control.