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 in other sectors, automation has brought about far-reaching changes in shipbuilding too. Digital systems, artificial intelligence and robots are transforming the design, construction and maintenance of ships, whilst increasingly taking on tasks in these areas.

In the German shipbuilding industry, automation is intended, in particular, to strengthen companies’ competitiveness. This transformation has economic and social implications and highlights which technologies and skills will become increasingly important in the future.

Shipbuilding remains a highly craft-based industry to this day. In the past, manual manufacturing processes dominated shipyards. Varied ship designs, large components and outdoor work made it difficult to standardise and automate many processes. Skilled workers were responsible, amongst other things, for cutting the steel plates to size, welding the sections and fitting out the interiors. Machines were also used for these tasks, but they were predominantly operated manually.

How has digitalisation changed ship design?

Digitalisation has opened up new possibilities for design and has supported further automation in shipbuilding. Paper-based drawings have increasingly been replaced by digital design models. These enable designers and engineers to design ships and components on a computer, simulate their properties and implement changes efficiently. The digital design data can also be used for downstream manufacturing stages.

What role do CNC machines play in modern shipbuilding?

CNC machines are a key component of automated manufacturing. CNC stands for „Computerised Numerical Control“. This technology enables, for example, metal sheets to be cut to size with precision according to digital specifications. Computer-controlled systems also carry out other tasks, such as welding. They complement manual manufacturing processes and replace individual work steps.

Shipbuilding in Germany is continuing to advance technologically. Digital manufacturing systems, robotics and AI-supported applications are opening up new opportunities to improve production processes. However, the extent to which these technologies are utilised varies depending on the shipyard, the type of vessel and the area of production.

Where are robots used in shipbuilding today?

The areas of application for robots in shipbuilding include welding, flame and laser cutting, painting and the assembly of components. They can relieve skilled workers of physically demanding or hazardous tasks and carry out repetitive work steps with a high degree of precision. Under suitable operating conditions, this accuracy is maintained even over extended periods of use. This requires appropriate programming, regular maintenance and the monitoring of process quality.

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

In the construction of naval vessels and cruise ships, welding robots offer particular advantages for easily accessible, repetitive welding tasks. With appropriate component preparation and optimised process parameters, they enable precise welds and consistent quality. Their high repeatability supports the reliable production of similar components.

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

Digital twins are virtual representations of ships, components or technical systems. They link digital models with relevant design, manufacturing or operational data. Depending on their design, they support the development, operational planning, maintenance and modernisation of a ship.

Simulations make it possible, for example, to investigate the flow behaviour of different hull and propeller shapes, as well as to estimate energy requirements and the stresses on components. Artificial intelligence helps to analyse data and identify suitable design options. On this basis, engineers can optimise the design of the actual vessel and incorporate reinforcements where necessary.

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

At the shipyard, Industry 4.0 refers to the digital networking of machines, systems and production processes. It ranges from planning and materials procurement through to final assembly and outfitting. Shared data helps to better coordinate the individual work steps.

Networking helps to identify sources of error and bottlenecks at an early stage. With appropriate data collection, deviations can be monitored in real time and corrective action taken promptly. This enables the teams involved to coordinate their work more effectively and minimise delays.

This enables skilled workers to install equipment and supply systems into the ship sections whilst they are still in the prefabrication stage, before these areas become more difficult to access once the hull is being assembled. Coordinated planning sets out which teams are to carry out work when, and what materials they will require. Digital systems can support this coordination.

What are the economic implications of automation in shipbuilding?

Automation has an impact on the profitability of German shipyards. It can increase productivity, optimise material usage and reduce manufacturing costs. This can strengthen competitiveness. However, the potential savings are offset by costs relating to procurement, integration, maintenance and training. Whether an investment is worthwhile depends, amongst other things, on capacity utilisation and the specific manufacturing tasks involved.

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

Automation improves a shipyard’s productivity and cost-efficiency. Robots and CNC machines take over suitable work steps, such as cutting steel plates to size or welding components. Digital control systems manage and monitor these processes. Depending on the application, the following benefits arise:

• greater accuracy and a lower error rate
• shorter lead times and more efficient production
• more efficient use of materials and less waste
• more consistent quality and potentially lower unit costs
• better planning and support for quality assurance
• Flexible adaptation to different production tasks using appropriately configured systems

To operate automated systems, shipyards require qualified specialists to programme, monitor and maintain them. This requires a combination of technical expertise and knowledge of digital control technology. If a company lacks the necessary skilled staff in-house, specialist temporary staffing agencies can help to meet staffing requirements on a temporary basis.

Why does repeatability improve quality in manufacturing?

A key advantage of automated processes is their high repeatability. Under the right conditions, robots repeat programmed sequences of movements with minimal deviation. This helps to ensure consistent production quality, particularly when carrying out repetitive tasks.

During welding, robots follow predefined movement paths and process parameters. If errors are detected, the causes must be investigated and, for example, the programming, component positioning or welding parameters adjusted. Even automated processes require ongoing quality control.

Well-coordinated automated processes improve manufacturing quality and reduce the amount of rework required, as well as minimising scrap. The extent of the savings depends on the specific process, the quality of the components and the existing manufacturing conditions. Fewer defective components and less rework lower production costs.

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

Digital networking makes it easier to coordinate work steps and plan suitable tasks in parallel. Automated systems also reduce the processing times of individual production steps. The extent to which this reduces the overall lead time depends, amongst other things, on available capacity, the supply of materials and the interdependencies between tasks.

Standardised and automated processes offer particular advantages where components are reused or where several vessels are built as part of a series. This may be the case, for example, when building similar ferries or naval vessels. However, the scale of the project alone does not make shipbuilding equivalent to mass production.

Automation also helps to make better use of capital-intensive plant. Robotic systems designed for this purpose enable long operating hours and multi-shift operation. To achieve this, maintenance, the supply of materials, process monitoring and the availability of qualified staff must be ensured.

Please note: Specialists in the programming, monitoring and maintenance of automated production systems may be deployed under a temporary agency work arrangement. In doing so, the legal requirements of the Temporary Agency Work Act (AÜG) must be complied with. 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 is transforming the German shipbuilding industry and complementing its traditional craftsmanship with digital and automated processes. CNC machines, welding robots, digital twins and networked production systems can improve precision, quality and productivity, as well as reduce lead times. Whether their use is economically viable depends on the specific manufacturing conditions and the investment and operating costs. Qualified skilled workers who combine traditional craftsmanship with digital control expertise remain crucial.

FAQ

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

Shipbuilding, which has traditionally been characterised by craftsmanship, has gradually been supplemented by mechanised, computer-controlled and digitally networked processes. Today, digital design models support the planning process, whilst CNC machines and robots carry out the relevant manufacturing steps. Specialist craftsmanship remains essential.

What role do CNC machines play in shipbuilding?

CNC stands for „Computerised Numerical Control“. CNC machines carry out machining operations according to programmed specifications and are used in shipbuilding, for example, to cut metal plates to precise dimensions.

Where are robots most commonly used in shipbuilding today?

Areas of application include welding, flame and laser cutting, painting and the assembly of components. The tasks carried out by robots depend on the shipyard’s equipment and the requirements of the specific production process.

What is a digital twin in shipbuilding?

A digital twin is a virtual representation of a ship or one of its systems, linked to relevant design, manufacturing or operational data. It can support development, simulation, maintenance and modernisation. Artificial intelligence can be used to complement data analysis.

What does Industry 4.0 mean for shipyards?

Industry 4.0 refers to the digital interconnection of machines, systems and production processes. In shipyards, it can improve coordination from the planning stage right through to final assembly and help to identify sources of error and bottlenecks at an early stage.

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

Automated processes can reduce errors, scrap and rework. The extent to which the error rate falls depends on the manufacturing process and the specific initial conditions. It is not possible to give a universal percentage figure without reliable data.

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

Automation can speed up individual production stages. Digital networking also makes it easier to coordinate and plan suitable tasks in parallel. The extent to which the lead time of a major project is reduced depends on the organisation, the available capacity and the supply of materials.

What sort of skilled workers are needed for automated shipyards?

There is a demand for skilled workers who combine practical craftsmanship with knowledge of digital control technology. Their duties include, for example, the programming, monitoring and maintenance of CNC machines and robotic systems.