Potential savings through automation in shipbuilding

In our article on the impact of automation on shipbuilding, we have already discussed the technological fundamentals. In this article, we explore the topic in greater depth and demonstrate specifically which Potential savings the costs incurred by shipyards in terms of materials, energy and man-hours – including a sample calculation for three shipbuilding projects of different sizes.

How does automated cutting reduce material waste?

Automated cutting and manufacturing systems can process components with precision and consistent quality. With appropriate programming and settings, this helps to reduce faulty cuts and material wastage. When cutting steel plates, precise cuts and an efficient arrangement of the components help to make better use of the available material. This can lower material costs and conserve resources.

How do intelligent nesting programmes improve resource efficiency?

Nesting programmes optimise the layout of the components to be cut out on a sheet of material, such as a steel plate. This allows better use to be made of the available surface area and reduces waste. This can lower material costs and contribute to more resource-efficient shipbuilding.

How does automation reduce the variable costs per component?

Automation can reduce variable costs per component by cutting labour, material consumption and rework. Optimised processes can be utilised repeatedly, particularly in the series production of standardised components and modules. The extent of the savings depends, amongst other things, on the complexity of the components, the utilisation of the equipment and the level of automation. Shipyards should therefore regularly record and analyse their actual labour and resource consumption.

How do data collection and documentation support quality management?

Automated manufacturing systems can record production data and make it available for analysis. Which work steps, assembly processes and welding parameters are documented depends on the technology used and its configuration. The data helps the relevant specialists to understand processes, investigate possible causes of faults and identify measures to improve the processes.

Digital documentation makes manufacturing processes more transparent. Insights gained from previous production data can help to identify sources of error before a new production run begins. If deviations are detected during production, specialists can investigate the causes and readjust the equipment if necessary. This helps to minimise the risk of recurring errors and reduce the amount of rework required.

Systematic data collection and documentation support quality management. They ensure that processes and test results are traceable and provide a basis for continuous improvement. The documented information can also serve as evidence during audits and certification procedures, provided it meets the relevant requirements.

Is automation also suitable for one-off production, such as yachts and research vessels?

Automation offers particular advantages in standardised and repetitive manufacturing processes. However, it may also be suitable for selected stages of work in the construction of individual yachts or research vessels. Digital planning, digital twins and, where appropriate, AI-supported methods can help to tailor processes to different components and requirements. Even custom-built vessels contain components whose manufacture involves recurring work steps. Whether automating these is cost-effective depends, amongst other things, on the programming and set-up effort required, as well as on the utilisation rate of the equipment.

In yacht and research vessel construction, automated processes can be combined with skilled craftsmanship. Suitable production stages are automated, whilst skilled workers carry out individual adjustments and complex assembly work.

Calculation example: How does automation affect the costs of three types of ship?

Using a small yacht, a medium-sized frigate and a large cruise ship as examples, we can illustrate how cost savings through automation can be calculated. The following figures are intended solely as simplified model assumptions. They are not indicative of the actual costs associated with these types of vessels.

The following assumptions apply to the model:

• The amount of manual work is reduced by 30 %.
• A cost rate of €35 per working hour is applied.
• Energy consumption falls by 10 %. The assumed energy price is €0.20 per kWh.
• The amount of off-cut has fallen by 15 % compared with the baseline figure.
• The proportion of working hours spent on post-processing is falling from 5 % to 1 %.

Two further specifications are required for the subsequent calculation:

• The original amount of off-cuts, or their material value, must be specified. A reduction of 15 % in waste does not equate to a reduction of 15 % in total material costs.
• It must be established whether the time saved on post-processing is already included in the 30 % working hours. Otherwise, there is a risk of double counting. Furthermore, the proportion of 1 % requires a clear reference value.

The following initial values are assumed for the three pilot projects:

Type of vessel	Working hours	Cost of materials	Energy consumption
Small yacht	20,000 hours	300.000 €	50,000 kWh
Medium-sized frigate	150,000 hours	€2.5 million	500,000 kWh
Large cruise ship	1.2 million hours	€25 million	5 million kWh

In order to apply the model to a specific shipbuilding project, the model assumptions must be replaced with project-specific data.

In the next article, we will use this as a basis to calculate the illustrative savings for all three types of vessel.

Please note: Even when operating automated production systems, qualified specialists for programming, monitoring and readjustment remain indispensable. These can be provided in a legally compliant manner through temporary agency work in accordance with the German Temporary Employment Act (AÜG). You can read more about this in our article on Temporary Employment Act (AÜG).. You can read about the technological foundations of automation in shipbuilding in our previous post on Automation in shipbuilding.

Conclusion

In shipbuilding, automation can reduce the workload, improve material utilisation and support quality management. Whether energy consumption is also reduced depends on the equipment and processes used. In addition to mass production, selected applications may also be suitable for the construction of bespoke yachts and research vessels. Key factors include suitable processes, qualified specialists and economically viable integration. The model assumptions presented here form the basis for the example calculation in the follow-up article. The actual extent of the savings must be determined for each project on the basis of specific data.

FAQ

How much can be saved on material costs through automated cutting?

Precise cutting and an optimised layout of the components on the steel plates can reduce material wastage and, consequently, material costs. The extent of the savings depends, amongst other things, on the component geometry and the previous level of material utilisation. It is not possible to specify a general percentage for this.

How much can automation save in mass production?

In the case of standardised components and modules, automation can reduce the variable costs per component. The extent of the savings depends, amongst other things, on the level of automation, the utilisation of the plant and the existing production processes. The figure of 30 % assumed in the calculation example refers to fewer manual working hours, not to the total variable costs.

What is the purpose of data collection in automated manufacturing processes?

Data collection makes documented manufacturing processes traceable and supports the investigation of the causes of defects as well as the continuous improvement of processes. The data collected can also serve as evidence for certification procedures, provided it meets the relevant requirements. The scope of the documentation depends on the system used.

Is automation also worthwhile for bespoke products such as yachts?

Automation can also be worthwhile for one-off production runs, particularly where there are recurring work steps or similar components. Whether its use is cost-effective depends, amongst other things, on the time and effort required for programming and set-up, as well as on the utilisation rate of the equipment. Automated processes and manual work can complement one another in this context.

What assumptions underlie this calculation example?

The simplified model assumes 30 % fewer manual working hours, a cost rate of €35 per working hour and 10 % less energy consumption at an energy price of €0.20/kWh. In addition, 15 % less material wastage and a reduction in the proportion of rework from 5 % to 1 % are assumed. These figures are for illustrative purposes only and do not represent general industry benchmarks.

How many working hours are required to build the example ships?

As baseline figures prior to the assumed automation, the model assumes 20,000 working hours for the small yacht, 150,000 for the medium-sized frigate and 1.2 million for the large cruise ship. These are illustrative model values, not general guidelines for these types of vessel.

Will skilled workers still be needed despite automation?

Automated systems must be programmed, monitored and, where necessary, readjusted, which is why qualified staff remain essential.