ADVANCED

OUTFITTING

Outline
Introduction to Outfitting
Zonal Design Work
Introduction to Advanced Outfitting
Types of Advanced Outfits
Benefits & Impact of Advanced Outfitting on Shipbuilding
Industry
Conclusion

Overview
Ship Construction
Structural
Component
Construction

Ship

Assembly
Rings(Grand
Blocks)

Blocks

Structural
Units

Outfitting

Outfitting
Installation of various systems & equipments
Allow the ship to operate and perform various missions
Occurs during construction of pieces that make the ship or once
those pieces are assembled
Structural

Outfitting

Piping
Electrical (power
distribution))
HVAC
Joinery
Painting & Insulation

Some
Some outfitting
outfitting must
mustbe
be done
done
during
during the
the building
building
Outfitting (Stages)

of
ofthe
the structural
structural units
unitsor
or
blocks
blocks
since ititwould
wouldbe
be
Pre-since
Outfitting
difficult
difficult and
and expensive
expensive later
laterin
in
const.
const. process.
process.

e.g.
Pipe-Work
in
Double
Bottom
e.g.
Pipe-Work
in
Double
Bottom
Performing
outfitting
task
early
in
the ship
Advanced
sections
construction process i.e. at unit, block or
sections
Outfitting
grand block stages

Occurs at the assembled stage and require works

Conventional to move to dry dock, slipway or land-level
Outfitting facility bringing with them materials &
equipments

Conventional Outfitting
Used to be one job after the other
Main Hull(outer shell) built
Equipments & Machinery lowered
Connected Piping work laid
Cables connected

Very slow
10% of piping and other outfit work were done when floated
Balanced fitting out in floating condition

Drawbacks
1

Did not facilitate optimum layout of

various systems

Difficulty of the task

Excess of Man-hours required

Obstructions in outfitting process

Reduction in productivity of the shipyard

Zonal Design Work

Outfit design is divided into Engine room, area other than
engine room and accommodation.
It reduces work by focusing on zones.
It forces all departments to pay attention to the planning and
interfaces in which they are involved.
It forces Production to take an active role early in the product
development.
Improved scheduling by early involvement of all
departments.
It promotes the use of multi-skilled teams.
Production efficiency is improved by performing all the
work, which can be done by the same workers at the same
time and same location.

Pre-requisites to Advanced Outfitting

The development of planning similar to the Shipbuilding
Policy and Build Strategy approach
Technical documentation format suitable for direct use
by Production
Highly trained workers
Decision making/planning delegated to appropriate level
Early involvement of Production in the design process
Concurrent development of product and process design
to facilitate maximum work in flat position

Advanced Outfitting
The fitting to ship structure, outfit items at a significantly
earlier time in the building sequence than is traditional.

Principle

Organization of information and materials to a plan

that applies labor and facilities to integrate ships
structure and outfit materials at the earliest and
most cost effective stage of the construction
process.
1.On-Unit
Types

2.On-Block
3.On-Board

Goals of Advanced Outfitting

Minimize on board outfitting
Reduce outfitting time
Simplify outfit planning
Avoid interference between trades
Improved use of cranes
Improved quality, productivity and worker safety

1.On-Unit Outfitting
On unit refers to a zone which
Definitio
defines
an
arrangement
of
fittings
to
n
be assembled in-house, independent
of hull structure. Assembly of such
fittings is called outfitting on-unit.
Enhances safety
Reduces both required man-hours and
durations which would otherwise be
allocated on outfitting on-block and
on-board
20% of the items are fitted in this
stage

Features

An Example

Seawater Service Pump And An Airconditioning Water Pump

Steps
Shown in previous slide is a machinery unit which will
contain both a Seawater Service Pump and an AirConditioning Water Pump.
Vertical Seawater Service Pump is fitted to the
subcontractor-furnished painted foundation which was
built according to a shipyard-provided detail drawing.
A pipe support, to be subsequently fitted, is included.
The horizontal Air-Conditioning Water Pump is on the
platen alongside are scheduled to be fitted on block.

A strainer has been fitted to the Seawater Service Pump,

the Air-Conditioning Water Pump has been fitted and a
valve is being lifted into position

A pipe piece is being lifted by the shop's bridge crane for

bolting to the Seawater Service Pump

A second worker temporarily assists by guiding a strainer

to its final position while the gasket and a few bolts are
secured

Pipe piece supports are being fitted

The completed unit is being transported for fitting on-block

2.On-Block Outfitting

Definitio The assembly of any fittings on any

structural subassembly (e.g. semin
blocks , blocks and grand blocks) is
referred to as an outfitting on-block.
On-Block outfitting purposes refer
to a rather flexible relationship between
block and zone.
The zone applies to a region being out
fitted. Following block turnover, the
fitting arrangement on deck is another
zone
50% of the items are fitted in this stage

Features

On Block
Advanced
Outfitting
Modular
Engine
Room
Outfitting

Advanced
Outfitted
Grand
Block

Examples

forecastle upside down

side shell and engine room

flat upside down

forecastle deck right upside up

aside shell and engine room

flat right side up

 Outfitting components , units, and grand units are

sometimes fitted in a block zone defined for hull
construction.
However, when they are to be fitted to ceilings, blocks
should be inverted because fitting down-hand enhances
safety and efficiency.
Following block turnover, the outfit zone encompasses
the components, units, and/or grand units fitted to the
floor.

Double Bottom On-block

Outfitting
Outfit items should be fitted in the zone of a double
bottom block before its tank top panel is installed.
At a later stage, a different outfit zone
everything to be fitted to the tank top.

encompasses

The primary goals of this manufacturing level are to

outfit ceilings and double bottoms when blocks can be
manipulated to provide ideal access.

Outfit Units
Engine room tank
top unit

Engine room tank top

components
fitted on-block

When the items to be fitted compose a small quantity per

block, outfit work can be performed at the site where the
block was assembled
When a large quantity is planned, the completed block
should be transferred to an indoor or outdoor region designated
for out fitting in accordance with an on-flow concept.
On-flow means work packages start and complete in unison
Separation by stage is in accordance with the following sequence
which reflects block turnover:

on-ceiling fitting
on-ceiling welding or nil
on-floor fitting
on-floor welding or nil

Divisions By Problem Area

It addresses problems which are inherently different.
Each work package for outfitting on-block can be
assigned to the appropriate team of assembly specialists.
These classifications are further subdivided by the
quantities of items to be fitted, resulting in the following
problem area divisions:
1
Hull
large
quantity /
small quantity

2
Machinery
large
quantity /
small quantity

3
Superstructur
e
large
quantity/
small quantity

Erection

Outfitted blocks can be erected in

combination with outfit units. On-block
outfitting work is often greatly facilitated by
block turnover for down-hand on-ceiling
outfitting and painting. Complex blocks may
be outfitted together to ensure accurate fits at
erection.

3.On-Board Outfitting
It can be defined as all the outfitting
Definitio
work
that
is
done
after
the
hull
n
blocks are completed and erected in
the slipway
or docks.
Conventional method
of outfitting
Only those heavy equipments which
cannot be erected at the general stage
are left to be done at this stage.
30% of the items are fitted in this
stage

Features

On-Board Outfitting(contd)
Ideally, assembly and painting work are left for
accomplishment on-board .
These works are limited to:
Fitting of components that are too large to fit on
block like main engine, diesel generators etc
Connecting distributive systems at block butts and
seams
Pulling only the ends of electric cables that were
fitted on block

On-Board Outfitting(contd)
Pulling electric cables that could not be
pulled on block
Connecting electric cables
Clean up
Painting touch up
Installation of the main drive line
Finish painting

Problems Faced

 A worker is performing fitting work of a certain

problem classification, on board.
The worker had to carry tools from the shop to the
relatively inaccessible and dark workplace.
In addition, the welding-cable leads had to be pulled
into position and thereafter the worker had to commute
from the shop, up the gangway, and down into the
machinery space.
The same work could have been performed in a shop
on-unit.

Fitting work of the identical problem classification

shown in is being performed on unit in a shop the
smart way.

 When traditional system-by-system work is

performed on board relatively out of sight of
supervision, workers pressed to meet a schedule
are prone to improvise and risk damage and
accidents.
Sometimes just the access to a work site is
dangerous in traditional system-by-system
outfitting of machinery spaces.

 On-board outfitting in the main machinery space of a

large vessel is facilitated by providing temporary
access through the shell. Otherwise, workers expend
significant energy ascending a gangway and climbing
down machinery-space ladders and vice versa.

Some shipyards have another type called Blue

Sky(Landing outfit on the ship under construction on the
berth before the compartment is decked over), but this is
really a subset of On Board.

Advanced Outfitting Practices-A

Comparison
UK shipbuilders lag
behind US and EU
shipyards in levels
of
advanced
outfitting in pipe
work, electrical, and
HVAC functions.

Current use of advanced outfit by UK,US and EU shipbuilders

Benefits of Advanced Outfitting

Reduced/eliminated overhead work
Improved access, (workers and material) ventilation and
lighting
Reduced/eliminated scaffolding
Improved tool/equipment availability
Reduction in time cycle and cost

20% Advanced
Outfitting
80% conventional
Outfitting

50% Advanced
Outfitting
50% conventional
Outfitting

80% Advanced
Outfitting
20% conventional
Outfitting

Recommendations*
Encourage shipyards to develop manufacturing plans that
strive to produce super blocks that are at least 80 percent
outfitted before they are sent to the assembly shipyard.
Involve all shipyards in the design process and encourage
the sharing of information on advanced outfitting
practices.
Ensure production designs are nearly complete before
construction begins and that the necessary equipment and
materials are available in a timely fashion to facilitate
advanced outfitting.
* By RAND Cooperation Europe

Impact on Shipbuilding Industry

Has modernized shipbuilding and its approach to facing
problems head on.
More and more computer applications are being resorted.
Exclusive softwares are being developed.
Modular construction
accommodation area.

is

getting

popular

esp.

The outfitting time after a ship has been floated out has
been reduced from 12 months to 2 months in countries
like Japan.

Conclusion
The introduction of new and appropriate technology
makes a big difference. In fact it is in going for
difference that will make a difference. Without training
there can be no technology upgradation, and without
technology upgradation ,there can be no competitive
edge. In absence of focus on technology we will be
working hard and not smart. Are we going to work hard
or work smart to be present in this decade and coming
ones?

Thank You !!