Automation in shipbuilding: Impact and cost-effectiveness

Automation in shipbuilding is fundamentally changing the way ships are designed, built and maintained – from CNC machines and welding robots to digital twins and Industry 4.0. If you are a shipyard or a supplier and would like to know how this transformation is affecting the industry economically and what skilled workers it requires, this article provides an overview of both the technology and the economic implications.

How has shipbuilding evolved from a craft to an automated industry?

As is the case across the manufacturing sector in all industries, automation has also brought about far-reaching changes in shipbuilding. As a result, ships are now designed, built and maintained differently. Digital systems, AI and robots are taking on an ever-increasing number of tasks at every stage of the process.

In the German shipbuilding industry in particular, automation serves to strengthen companies’ position in the face of international competition. This transformation is having economic and social implications and is already shaping key trends for the future.

Shipbuilding was, and remains, a craft-based industry. Consequently, manual production processes used to predominate on shipyards. The ships were all different, the components were enormous, and construction often took place outdoors. Consequently, there wasn’t necessarily much scope for the first machines to play a part in the manufacturing process. In other words, people were responsible for cutting the steel plates to size, welding the sections together and carrying out the entire interior fit-out. Machines, if they were used at all, were controlled manually.

How has digitalisation changed ship design?

But then came digitalisation, which heralded the dawn of automation. Until then, individual ships and structures had been drawn exclusively on paper. Now, designers and engineers were able to model them digitally. This meant they could be tested and planned more effectively on the computer, and their drawings could be produced with much greater precision.

What role do CNC machines play in modern shipbuilding?

Then came the introduction of CNC machines. CNC stands for „Computerised Numerical Control“. These machines were capable of producing precise cuts from metal sheets. They were also capable of operating in automated welding systems. This marked the beginning of the process of supplementing – and, in some cases, replacing – purely manual work with new processes.

At present, the shipbuilding industry in Germany continues to undergo rapid change. Change is currently the only constant within these companies. New digital manufacturing systems, robots, AI-controlled systems and the like are now finding their way into every part of the industry.

Where are robots used in shipbuilding today?

Robots are widely used in various welding processes, flame and laser cutting, the application of paint finishes, and the precise assembly of parts. They prove their worth here, as they can, in some cases, keep people away from these hazardous tasks and can often carry them out with much greater precision. The latter applies not only to a single moment, but also to work lasting hours or even days. Where humans tire and make mistakes, a welding robot can still produce precise welds even after twelve hours.

How do naval vessels and cruise ships benefit from welding robots?

Robots with their arms are particularly well suited for use on naval vessels and large cruise ships. They produce precise, high-quality welds. Above all, however, they can repeat these tasks as often as required whilst maintaining the same level of precision and quality.

What are digital twins, and how does AI use them?

Digital twins are computer-based representations or models of real ships. These models resemble the real ship they represent and are used to plan construction, maintenance, upgrades and operation.

Artificial intelligence can now work with these models. To do so, it simulates, for example, flow behaviour in order to identify better hull and propeller designs. The AI can also calculate energy consumption and determine material stress. This allows for more accurate planning of the digital twins. Instead of, for example, reinforcing critical areas too weakly and non-critical areas too strongly, engineers can plan reinforcements precisely where they are actually needed throughout the ship’s service life.

How does Industry 4.0 link the various stages of production at the shipyard?

The principles of Industry 4.0 are also making their way into shipyards. This involves fully interlinking the individual production stages and tasks. This ranges from planning and materials procurement right through to final assembly and outfitting. Thanks to this interlinking, these many individual steps are transformed into a single, continuous process.

Linking all the steps together makes it possible to identify sources of error and, above all, to avoid bottlenecks from the outset or to plan for them in such a way that they do not have a negative impact on the overall process. Any errors that do occur can be detected directly in real time and rectified immediately. The individual tasks in each phase are carried out in tandem, so that they support rather than hinder one another.

For example, once the segments arrive from the prefabrication stage, the specialists install the equipment and supply systems together on site before access is blocked off or restricted by the assembly of the hull. Planning the entire process as a single operation can thus bring together different teams responsible for different tasks, who then work together on site.

What are the economic implications of automation in shipbuilding?

Automation in the German shipbuilding industry is a technological factor that also has significant economic implications. These range from improved cost-efficiency and increased productivity to competitive advantages, the supply chain and various support schemes.

What are the benefits of automation in terms of cost-efficiency and productivity?

Automation is one of the most important factors in boosting productivity and, consequently, cost-efficiency. In the past, shipyard workers carried out many tasks manually. These ranged from plasma-cutting individual steel plates to welding the various sections together. Today, robots carry out these tasks, as do digital control systems and CNC-controlled machines. The resulting benefits lead to cost savings and higher productivity. These consist of:

• Greater accuracy and a lower error rate
• Faster turnaround times and more efficient production
• Improved use of materials
• Consistent quality at lower unit costs
• Improved planning and quality assurance
• Flexibility even with complex processes

Shipyards that operate these automated systems require qualified staff to programme, monitor and maintain them. It is precisely this combination of traditional craftsmanship and digital control expertise that is often in short supply on the labour market and can be effectively supplemented through specialised temporary staffing agencies.

Why does repeatability improve quality in manufacturing?

Automated processes offer many advantages, but one of the most important is often overlooked. Thanks to automation and precise control, they can be repeated as often as required. Whereas a human being constantly introduces small, new variations with every repetition, a robot repeats the process over and over again with millimetre precision.

The robots, for example when welding, follow a predefined plan. If errors occur, the plan can be adjusted. This continues until it is perfected, and then the robots repeat the instructions with every pass. This takes place without fatigue and regardless of external conditions.

The result is a significantly higher standard of quality. This means that welds hardly need any further finishing, and the amount of scrap in parts production is considerably lower. In practice, defects can be reduced by up to 70 %, which is naturally also reflected in production costs.

How does automation reduce lead times on large-scale projects?

Once the production systems are digitally networked, they can carry out various work steps in parallel. This enables them to complete the same work in a much shorter time. Whereas ship sections used to take weeks to complete, this can now be reduced to a matter of days.

This is particularly worthwhile for large shipyards. Production here is akin to mass production, given the scale of the projects and the number of orders. This is particularly the case, for example, with ferries and naval vessels. Carrying out the work in parallel results in time savings that quickly add up.

Furthermore, automation makes it possible to utilise even expensive equipment much more efficiently. Robots can work round the clock without any problems and without compromising on quality.

Please note: Skilled workers who programme, monitor and maintain automated production systems can be placed through temporary agency work in accordance with the German Temporary Employment Act (AÜG) in a manner that complies with legal requirements. You can read more about this in our article on Temporary Employment Act (AÜG).. To find out how digitalisation and continuing professional development go hand in hand, read our article on Digitalisation & Further Training in Shipbuilding.

Conclusion

Automation has transformed German shipbuilding from a purely craft-based trade into a highly networked, digitally controlled industry. CNC machines, welding robots, digital twins and Industry 4.0 connectivity measurably increase precision, quality and productivity – whilst also reducing lead times and improving cost-efficiency. For shipyards, this also means a growing need for skilled workers who combine traditional craftsmanship with digital control expertise.

FAQ

How has shipbuilding evolved from a craft to an automated industry?

Manual manufacturing processes used to dominate, until digital design models and, later, CNC machines complemented and, in some cases, replaced manual labour.

What role do CNC machines play in shipbuilding?

CNC stands for „Computerised Numerical Control“ and enables the precise cutting of metal sheets and the operation of automated welding systems.

Where are robots most commonly used in shipbuilding today?

Particularly in welding, flame and laser cutting, painting and the precise assembly of parts, especially on naval vessels and large cruise ships.

What is a digital twin in shipbuilding?

A digital twin is a computer-based representation of a real ship, which is used for planning, maintenance, upgrades and simulations involving artificial intelligence.

What does Industry 4.0 mean for shipyards?

Industry 4.0 links all stages of production, from planning to final assembly, into a continuous process, enabling sources of error and bottlenecks to be identified at an early stage.

To what extent does automation reduce the error rate in shipbuilding?

In practice, automated, repeatable processes can reduce errors by up to 70 %, which also significantly cuts production costs.

How does automation affect lead times for large-scale projects?

Digitally networked manufacturing systems can carry out work steps in parallel, thereby reducing the time taken to complete ship sections from weeks to days.

What sort of skilled workers are needed for automated shipyards?

There is a demand for skilled workers who can combine traditional craftsmanship with digital control expertise, for example in the programming, monitoring and maintenance of CNC machines and robotics.