Digitalisation & Further Training: Productivity in Shipbuilding

Digitalisation in shipbuilding is transforming the way shipyards plan, manufacture and ensure quality – from digital twins and connected machinery to welding robots. If you are a shipyard or supplier and would like to know how these technologies specifically boost productivity and what role further training plays in this, this article will give you an overview. It becomes clear that digitalisation does not replace skilled workers, but it does significantly raise the bar in terms of the qualifications required of them.

How is digitalisation changing production methods in shipbuilding?

The digitalisation of shipbuilding is bringing about changes to individual production methods. Examples of this include „Building Information Modelling“ (BIM), digital twins and real-time data monitoring. This enables individual processes to be tracked more accurately, planned for the future and managed in the present.

How do digital dashboards improve material flow and communication?

Digital dashboards make it possible to monitor the flow of materials. They also track energy consumption and the progress of work in real time. This makes it possible to respond immediately to errors and optimise processes for the future.

Furthermore, they improve communication between departments. This enables the various teams to coordinate their individual processes and, in turn, avoid errors and waste.

What role does continuing professional development play in technical progress in shipbuilding?

Technological progress brings many benefits. These include new machines that enable work to be carried out more efficiently, new materials that offer greater safety, lower weight and increased strength, new processes that optimise production, and the list goes on. However, they also bring their own set of challenges. In order to capitalise on these various benefits, staff must possess the necessary specialist knowledge. This is where further training and staff qualification come into play.

Continuing professional development in shipbuilding applies to all specialists and disciplines, whether they are welders, electronics technicians, mechanics or engineers. They all face the ongoing challenge of familiarising themselves with new materials, operating new machinery and learning new processes.

How are training courses for welders, electronics technicians, mechanics and engineers organised?

During training courses, staff learn how to operate laser cutting machines, automated welding systems and digital control systems. These are now standard equipment, but they are constantly evolving. In refresher courses, staff learn about the latest changes, practise applications they do not use all the time but which are nevertheless important from time to time, and generally keep their knowledge up to date.

Why is interdisciplinary training becoming increasingly important?

In addition, interdisciplinary training is becoming increasingly important. Mechanics who also have some knowledge of electronics can be deployed flexibly. The same applies to electronics technicians who are now better able to work with mechanical systems. This also fosters an understanding of the work carried out by other team members, which will aid future collaboration and measurably increase productivity.

How do employees benefit from certified qualifications?

The training courses themselves must meet a certain standard of quality, and participants must be awarded a certificate upon successful completion. This fosters a greater sense of responsibility and increased motivation amongst the workforce.

Staff can see their progress and demonstrate it. They develop into experts, which improves their career prospects, increases their salary and makes them more valuable to the business. This allows them to see for themselves how they are developing and the benefits this development brings them.

How do partnerships with vocational colleges and universities strengthen continuing professional development?

This goes hand in hand with cooperation with vocational schools, universities and further education centres. On the one hand, this ensures that the shipyards have a sufficiently qualified workforce of young people; on the other, it helps to build a bond with the trainees. These trainees are then more likely to go on to work at the cooperating shipyard. Furthermore, such partnerships also facilitate the further training of shipyard staff.

Technological change offers many new ways to boost productivity in shipyards. Digital planning tools, automation and process simulation, in particular, enable rapid improvements. At the same time, they help to reduce errors and improve the overall quality of the work.

Is automation replacing staff at the shipyard?

Automation in shipyards is not designed to replace people, even though it is often portrayed that way. In fact, a look back at history shows that, whilst the advent of machinery has changed the labour market, it has never put people out of work. Instead, employees have continued to develop their skills. With the help of machines, a single worker was able to do the work of several. As a result, companies expanded production rather than simply laying off staff.

How are robots changing the work of welders?

The situation is much the same today: robots work more precisely and quickly than humans ever could. Instead of employing large numbers of welders to produce mediocre welds, companies now employ welders for just two main tasks: one group monitors the robots and ensures they are operating to the required standard. The other group carries out welding wherever robots cannot operate. As a result, general welders are developing into specialised professionals, thereby gaining higher qualifications and higher pay – without any redundancies.

The same applies to all other areas where robots take over the work. They ensure greater speed and higher quality, and are particularly found in situations where the work is monotonous – and therefore prone to errors – or dangerous. This means that staff are spared such tasks and can concentrate on what humans do better than machines.

A good example of the use of robots is the manufacture of the individual sections of a ship. They can be used to position the heavy plates with precision. The robots then weld them together, after which an automatic inspection is carried out to ensure the quality of the welds. This significantly reduces the amount of rework required.

In terms of workforce planning, this means that there is a growing demand for welders and technicians who are proficient in both traditional craftsmanship and the monitoring of automated systems. Shipyards that do not have enough of these dual-skilled specialists in-house often source them specifically through specialist temporary employment agencies.

Which digital tools can be used to simulate the manufacturing process in advance?

Digital tools, such as 3D CAD systems, make it possible to simulate the individual manufacturing processes in advance. This enables production managers and design engineers to identify and prevent potential bottlenecks.

Smart Ships simulation – in other words, virtual ships – enables test runs, maintenance planning and even training. This means, for example, that shipyard staff can walk through the virtual engine room without having to use a real ship.

What are connected shipyards and how do they reduce downtime?

Digitalisation in shipbuilding is giving rise to connected shipyards. Here, machines work alongside sensors and tools. They communicate with one another, report their status in real time and enable immediate intervention in the event of faults. They can also be used to schedule maintenance automatically. They also automatically manage the supply of materials. This reduces downtime, for example during repairs or whilst waiting for new materials.

Please note: Skilled workers with experience in digital manufacturing processes and automation can be placed in roles in a legally compliant manner via temporary agency work under the German Temporary Employment Act (AÜG). You can read more about this in our article on Temporary Employment Act (AÜG).. To find out how shipyards can attract and retain skilled workers, read our article on Recruiting skilled workers in shipbuilding.

Conclusion

Digitalisation and further training are closely intertwined in shipbuilding: BIM, digital twins, automation and robotics measurably boost productivity, but at the same time require a continuous supply of skilled workers. Those who invest in training courses, interdisciplinary training and partnerships with educational institutions secure a workforce capable of utilising these technologies effectively – without any job cuts, but with higher qualifications and better pay for employees.

FAQ

What is meant by digitalisation in shipbuilding?

These include technologies such as Building Information Modelling (BIM), digital twins, real-time data monitoring and digital dashboards, which make production processes more predictable and transparent.

Is automation replacing skilled workers in shipbuilding?

No. Historically, technological progress has never displaced workers, but has instead changed the nature of their work and expanded production as a whole, usually leading to higher qualifications and pay.

How are robots changing the welding profession?

Welders are increasingly taking on the role of supervising welding robots or specialising in welds that robots cannot perform, which leads to higher qualifications and better pay.

What further training do skilled workers in the digitalised shipbuilding industry need?

There is a demand for training courses on laser cutting machines, automated welding systems and digital control systems, as well as interdisciplinary training, for example for mechanics with knowledge of electronics.

What is a Smart Ships simulation?

This is a virtual model of a ship that can be used to carry out test runs, maintenance planning and training without the need for a real ship.

What does a „connected shipyard“ mean?

Machines, sensors and tools communicate with one another, report their status in real time and enable automatic maintenance planning and material replenishment, thereby reducing downtime.

Why are certificates important in further training in shipbuilding?

They demonstrate a defined standard of competence, foster a sense of responsibility amongst staff, and improve their career prospects and salary.

How can you find skilled workers with experience in digitalised manufacturing processes?

In addition to in-house training and partnerships with educational institutions, suitably qualified specialists can also be recruited on a project-by-project basis through specialist temporary employment agencies.