INTELLIGENCE + TECHNOLOGY IN THE MODERNIZATION AND AUTOMATION OF NEW AND EXISTING SHIPYARDS

From my own experience over the years, and that obtained from MARTEC Engineering, a specialized company providing high level modernization and automation solutions to the ship building industry, -particularly Shipyards-, I will try to make a brief observation and comments on those aspects I consider to be the most interesting.

Automation is a system, where, the production tasks usually performed by humans are transferred to a set of technological elements. It consists of two different parts:

The Operational part is the part that acts directly on the machine. These elements make the machines work and perform the desired operations. These are the driving machine operative elements: motors, cylinders, air compressors, welding & cutting elements, markers, sensors as photodiodes, robots, etc.

The Command Part is usually a PLC (Programmable Logic Controller). In an automated manufacturing system, the programmable automaton is the brain of the system and must be capable to communicate with all the elements of the automation system.

Objectives of the modernisation/automation

Before implementing an advanced automation system, it must be clearly understood as well as be convinced that a number of targets will be mainly achieved:

1. Great improvement of levels of productivity in terms of reducing cost and improving quality
2. Production increase
3. Improve of working and safety conditions by elimination of arduous works.
4. Rationalize the transfer of pieces (plates, profiles, panels, subassemblies, sections, blocks etc.)
5. Perform operations impossible to control intellectual or manually
6. Improve availability providing requested amounts at the right time
7. Simplify maintenance. Operators do not require great knowledge for the process
8. Integrate management and production

My experience in data

Spanish shipyards – Sestao, Ferrol, Puerto real, Sevilla, Juliana… The automated equipment together with the modernisation concepts implanted by MARTEC in these shipyards, allow me to see first hand, and make myself a site composition in this regards.

The first conclusion I draw is the incomparable and surprising quality of the work achieved, which affects directly and very positively to the product itself as well as to the following processes of production, particularly when in tier. A small error at first stage, say in drawings, cutting, welding etc., becomes a huge problem (and cost in hours) during the assembly process. The automation provides the precise quality to eliminate these initial errors.

It is true that to achieve this, among other things, the Shipyard must have a powerful technical office capable to generate reliable final drawings to be then transferred to the Command Part (software) system in real time in order not to stop or create any disturbance to the production chain.

The increase of production and productivity depends on the Shipyards investing decision in modernisation/automation, moving it forward in the same proportion as the ship delivery.

The saving in the line construction of the blocks and the time saving during assembly process in the tier, might be well about 15% of the total time of the steel work (hull). The quality achieved and the well controlled process is directly involved in these savings, preventing in this way having to make costly correction and reforms afterwards.

Another very important aspect to be considered is the significant improvement obtained in safety at work. Since blocks move online, the possibility of accidents caused by plates, panels, subassemblies blocks etc in suspension, are drastically minimized. This point is of utmost importance since, apart from the drama and tragedy that represents each accident or casualty, the productive and economic impact generated is absolutely negative for the Shipyard. I have found that workers are more focused on their job and also more efficient, because they know that the processes are safe and they do not have to take any risks of moving pieces, which forces them to be in a constant vigilance.


The rationalization of materials handling and moving is another point to bear constantly in mind. A huge amount of hours are lost in the transfer of different material and parts when the shipyard workshop is not well organized in conjunction with the equipment installed or to be installed. Depending on each case, the efficiency of the mobilization might be improved between 10 -20%.


No doubt that the implementation of an automated system reduces personal, but the staff required should be more qualified and should be trained and familiarized with computer control environment. Even so, the balance is always positive and this will benefit the shipyard productivity.

As a preliminary summary, from my point of view, nowadays in order to compete in shipbuilding industry at a global level, the Shipyards do not have any other option than get modernized, undertaking the necessary investments to innovate by implementing automation. There is NOT other way. Therefore, the most increase in production and productivity the most reduction of the ratio Hours/Ton, which, in one word, is the most crucial Ratio for a shipyard.

In this complex shipbuilding field, the only company, that I know, capable to modernize/automate the Shipyards, making their complete turn key integration, is MARTEC Engineering.

Today, more than ever, to be competent, one must get trough modernization and reduction of production costs .

Sometimes I think that the intelligence-technology relationship is more than just the application of the equation Intelligence + technology = automation/modernization.