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?

Systems for automated cutting and automated manufacturing operate using a programmed control system that functions far more precisely than a human ever could. This not only improves the quality of the end product, but also reduces the waste of materials and resources. One example of this is the cutting of steel plates: thanks to greater precision, there is far less off-cut. This means that more of the steel is actually used in the ship’s construction, which in turn reduces material costs and, of course, benefits the environment.

How do intelligent nesting programmes improve resource efficiency?

So-called intelligent nesting programmes increase this precision even further. As well as reducing material costs, they also improve resource efficiency. This, in turn, is an important aspect in the pursuit of sustainable shipbuilding.

How does automation reduce the variable costs per component?

Automation reduces the variable costs per individual component. This is because the processes are first optimised and can then be repeated as often as required thanks to the programming. This results in significant savings, particularly in the mass production of various modules or individual, standardised components and systems. These can often reach up to 30 %. However, the actual extent of the savings also depends on the complexity of the parts and the degree of automation integration; consequently, resource consumption in the shipyards must be constantly monitored.

How do data collection and documentation support quality management?

This is precisely why automation relies on the collection and analysis of production data. The programmes document every step, every assembly movement and every weld seam in detail. This enables designers to track what is happening and to identify where defects might occur, what causes them, and how such faults can be prevented in future.

Automation therefore not only controls production; through its documentation, it also ensures a whole new level of transparency. This makes it possible to identify sources of error even before production begins. However, if these only become apparent during production, the specialists can readjust the equipment. This prevents the errors from recurring in the next production run, thereby naturally saving labour and other resources.

This way of working also ensures consistent quality management. Comprehensive documentation serves as evidence and forms the basis for improvements. It also facilitates traceability and the certification of processes and products – which is also highly regarded.

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

Many people view automation as a development that is only worthwhile for standardised products. In this respect, they are – or were – not necessarily wrong. However, times have changed somewhat, and nowadays there are many more factors to take into account. Today, digital twins and AI-supported planning make it possible to integrate non-repetitive manufacturing processes into software. This means that, with such adaptive systems and supported by digital planning, automated systems can now also operate quite easily in the manufacture of one-off vessels. Furthermore, even within these one-off vessels, there are components whose manufacture involves repetitive processes.

This means that, these days, automation is already evolving into a hybrid model. It can also be applied to yachts and research vessels, as its capacity for bespoke manufacturing now complements traditional craftsmanship.

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

Here is an example of how automation can affect the costs of a project. To illustrate this, we will use a small yacht, a medium-sized frigate and a large cruise ship as the basis for our calculations. Here are the assumptions used in this example:

• The overall saving amounts to – based on a conservative estimate – 30 % fewer manual working hours
• The pay for the work is €35 per hour
• In the energy sector, the automated processes save 10 % at an assumed price of €0.20 per kWh
• Material waste is 15 % less
• Post-processing has fallen from 5 % of total working hours to just 1 % thanks to automation and the resulting increase in precision

For the three ships in the example, this effort is the baseline figure:

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

These figures can, of course, be replaced with actual values based on a real-life example if someone wishes to apply the calculation to a specific shipbuilding project.

In a subsequent article, we will continue this calculation and analyse the specific savings for all three types of vessel in more detail.

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

Automation in shipbuilding not only saves time, but also delivers measurable savings in materials, energy and man-hours – from more precise cutting and intelligent nesting programmes to seamless data collection for quality management. Thanks to digital twins and AI-supported planning, even bespoke vessels such as yachts and research ships now benefit from these advantages. The calculation example for a yacht, a frigate and a cruise ship illustrates the exact scale of the savings – and this will be explored in greater depth in the next article.

FAQ

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

Greater precision and less waste when cutting steel plates lead to a noticeable reduction in material costs, although the exact figure depends on the complexity of the parts.

How much can automation save in mass production?

With standardised components and modules, the savings in variable costs per component can often reach up to 30 %.

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

It provides comprehensive documentation of every step in the process, enables the traceability of defects and their causes, and forms the basis for continuous process improvement and certification.

Is automation also worthwhile for bespoke products such as yachts?

Yes. Digital twins and AI-supported planning now make it possible to automate even non-repetitive manufacturing processes, so that automation and craftsmanship complement one another.

What assumptions underlie this calculation example?

30 % fewer manual working hours, an hourly wage of €35, 10 % in energy savings at €0.20/kWh, 15 % less material waste and a reduction in rework from 5 % to 1 % of working hours.

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

In the example, the figures are 20,000 hours for the small yacht, 150,000 hours for the medium-sized frigate and 1.2 million hours for the large cruise ship.

Will skilled workers still be needed despite automation?

Yes, automated systems need to be programmed, monitored and, where necessary, readjusted, which is why qualified staff remain indispensable.