Advanced Outfitting Techniques for Shipyard Development: A 2000 GT Shipbuilding Case Study

The shipbuilding sector is currently facing issues due to long manufacturing schedules and delays in ship construction completion. These challenges come from national shipyards' conventional onboard outfitting process for equipment installation, which takes a lengthy time to complete. To address this issue, this study proposes implementing the advanced outfitting system (AOS) approach, which combines the zone outfitting system with the hull block construction method, in building a 2000 GT ship at PT. X in Surabaya, Indonesia. Technical analysis is performed to plan the shipbuilding process using the hull block construction method, and the efficiency of man-hours is calculated by implementing the AOS approach. The study also conducts an analysis of shipbuilding costs and the required shipyard development investment. The technical analysis shows that the AOS approach improves efficiency factors by enhancing material handling and testing activities. The AOS method has an efficiency factor of 50% for on-unit outfitting and 62% for on-block outfitting, compared to on-board outfitting. The construction of a 2000 GT ship employing the AOS approach represents a reduction of approximately 9.6% in working days and a cost-saving of approximately 4.3% when compared to the onboard outfitting method, resulting in savings of 1DR 1,933,277,000 or about USD 124,175. To implement the AOS approach, an investment of IDR 3,040,776,000 or about USD 1 95,31 0 is required for construction facilities and human resources development. The return on investment is obtained after two 2000 GT ships are completed. As a result, the AOS approach can improve shipbuilding productivity by reducing construction time and costs. This study provides insights into the benefits of implementing modern shipbuilding techniques in the industry.


Introduction
The shipbuilding sector is characterized by intense competition, necessitating shipyards to consistently enhance their operational efficiency and productivity in order to maintain a competitive edge [1], The efficiency of shipbuilding is influenced by various factors, including building technique, resource ability, and management level [2], Therefore, it is important to develop an efficiency evaluation model based on these driving factors to analyze and improve shipyard performance.In Indonesia, the shipbuilding industry currently faces challenges related to long production times and delays in completing ship construction.The construction of one ship can take up to 24 months, with delays often occurring during the process.These issues stem from the traditional onboard outfitting method used by national shipyards for equipment installation, which takes longer to complete than alternative methods.
One of the key areas of shipyard development is the implementation of advanced outfitting methods.The outfitting process in shipbuilding, especially for complex vessels, is characterized by disorganization and rework due to a lack of coordination [ 3].By applying advanced outfitting methods, such as lean production principles and process-centric simulation modeling, shipyards can optimize the outfitting process, reduce waste, and improve overall productivity [4], [5], Furthermore, the integration of digital technologies, such as radio-frequency identification (RFID) [6], indoor positioning systems (IPS) [7], wearable device for welder recognition [8] and QR-Code technology [9], [10] can enhance the efficiency and visibility of shipyard operations [11], These technologies enable real-time monitoring of various parameters, such as CO concentration and location tracking, which can help in identifying and addressing bottlenecks and improving overall operational performance.

Figure 1
Kapal: Jurnal Ilmu Pengetahuan dan Teknologi Kelautan, 20 (3) (2023):329-342   To address this challenge, there is a need for a new shipbuilding method that can reduce production time and costs.The advanced outfitting system, proposed by Rajko Rubesa [ 12], is an innovative approach that can significantly reduce the time and cost of outfitting installation.The simulation model of this method provides a comprehensive analysis of the decrease in direct outfitting working hours when using various block delivery methods in an assembly shipyard [2], With this technique, shipbuilding can be completed faster, cheaper, and more competitively without requiring the purchase of additional buildings, equipment, or tools [12].
Some research about shipyard technological level of development has been published.Rubesa developed criteria for evaluating technological level of ship pre-outfitting [13], The technological level of ship pre-outfitting can be evaluated based on various criteria, including equipment capabilities, automation level, integration of information systems, availability of advanced tools and software, and employee expertise.These criteria help assess the shipyard's ability to efficiently and effectively carry out pre-outfitting activities, ensuring quality and timely completion.Furthermore, Zhou et al developed Lean Production of Ship-Pipe Parts Based on Lot-Sizing Optimization and PFB Control Strategy [14], Lean production techniques, including lot-sizing optimization and PFB (Production Flow Balance) control strategy, can significantly improve the production process of ship-pipe parts.By optimizing lot sizes, shipyards can minimize waste, reduce inventory, and improve overall production efficiency.
In measuring shipyard performance, Semini analyses the relationship between build strategy and shipbuilding time [15], Factors such as modular construction [16], concurrent engineering, prefabrication, and the use of advanced production techniques impact the overall efficiency and productivity of the shipbuilding process.By adopting lean principles and optimizing the build strategy, shipyards can reduce construction time, minimize costs, and enhance overall performance.In addition, Baihaqi combines value engineering and risk assessment methodologies to measure shipyard performance [17], Value engineering focuses on optimizing costs, quality, and functionality, while risk assessment helps identify and mitigate potential risks and uncertainties.The integration of these approaches provides a comprehensive evaluation of shipyard performance, enabling effective decision-making and continuous improvement.
The main objective of this research is to provide a technical and economic analysis of the implementation of the advanced outfitting system in shipbuilding.The analysis includes an assessment of the necessary shipyard preparations to apply this method, as well as the expected reduction in construction time and costs.The novelty of this research lies in the comprehensive analysis of shipyard development using advanced outfitting methods for the 2000 GT shipbuilding process.
While previous studies have focused on specific aspects of shipyard development, such as efficiency evaluation [ 1 ], location selection [18], or energy management [19], this research aims to provide a holistic analysis by considering technical, economical, and operational aspects.
By conducting this analysis, the research aims to provide valuable insights and recommendations for shipyards to enhance their development strategies and improve their competitiveness in the shipbuilding industry.The findings of this research can contribute to the body of knowledge in shipyard development and serve as a reference for future studies in this field.330

Identification of Problems
In the initial stage of this study, a thorough identification of problems is carried out.This involves conducting a literature review and field studies to understand the current state of the shipbuilding industry in Indonesia.The objective is to identify the key challenges and issues that are hindering the development of the industry, and to seek solutions that can improve its overall efficiency.In addition to identifying problems, this study also involves an assessment and evaluation of the technical and economic aspects required for the development of the shipyard.This includes an evaluation of the current shipbuilding processes, as well as an analysis of the costs associated with each process.By conducting a comprehensive analysis of these factors, we can develop a better understanding of the technical and economic feasibility of implementing new shipbuilding methods and technologies.Overall, the identification of problems and the assessment of technical and economic aspects are critical steps in developing a more efficient and competitive shipbuilding industry in Indonesia.Through this study, we aim to provide insights and recommendations that can help the industry to overcome its current challenges and achieve sustainable growth in the long term.

Comprehensive Review of existing method and proposed method
A thorough literature study was conducted in this research, aimed at understanding the concepts and appropriate methods to solve the problems identified in the previous stage.The study covered a wide range of references related to the research topic, including previous research, theories, and practices related to ship construction, outfitting installation, and shipyard development.By conducting a comprehensive literature study, this research aimed to gain a deeper understanding of the current state of the shipbuilding industry and to identify best practices and innovative approaches that could improve its overall efficiency.The study also helped to identify gaps in the existing literature and to suggest areas for future research.

Shipbuilding with HBCM
Shipbuilding requires a long and time-consuming process.One of the shipbuilding methods is HBCM (Hull Block   .This method allows construction to be faster because ship construction can be Construction Method) as shown in carried out simultaneously by blocks.The following diagram is a development processes using the Hull Block Construction Method [20],

Outfitting Installation Process
The outfitting installation method is divided into several categories based on the time of installation [3], Another term for this installation process is the zone outfitting method.The following are several categories of ship outfitting installation [20], [21], 1. On-unit outfitting: the process of installing ship outfitting that was carried out in the equipment unit itself.
Equipment and supplies are made into one outfit unit.The assembly process is carried out in the workshop.2. On-block outfitting: the process of installing ship equipment that was carried out during the block assembly process.
The form of ship equipment and supplies can be in the form of an outfitting unit or the smallest component of outfitting.3. On-board outfitting: the process of installing ship equipment at the building berth when the erection process is carried out, or when the ship has just been launched.Ship equipment that is installed on-board is anything that cannot be installed on-unit and on-board.

Advanced Outfitting System
Advanced outfitting system (AOS) is a shipbuilding method by installing equipment as much as possible before the erection process is carried out [2], AOS is a shipbuilding method that combines the hull block construction method and the zone outfitting method to build ships [12], The outfitting installation process is prioritized in the following order: on unit outfitting, on block outfitting, and then on board outfitting [22], The outfitting installation process in each Zone-Outfitting- Method (ZOFM) has its own efficiency factor.This efficiency factor is influenced by the ease of processing and faster material handling time as shown in Figure 2. Some of the advantages of the AOS method are as follows: Fabrication and installation of outfitting at the beginning can reduce the workload of concentration work at the end of shipbuilding.
Increase the safety factor of work because it is done in the workshop.The installation of outfitting is done in a position that makes it easier for workers.
The equipment workshop environment allows for cleaner, higher-quality work.
Increase the efficiency factor of outfitting installation as described in Figure 2. Efficiency improvement in advanced outfitting system Overall, the literature study played a critical role in achieving the research objectives by providing valuable insights and knowledge related to shipbuilding processes, outfitting installation, and shipyard development.By building on the existing literature and previous research, this study aimed to contribute to the advancement of the shipbuilding industry in Indonesia and to help address the challenges facing the industry in the present day.

Data Collection and Management
After understanding the concept, the author collects data related to ship production planning using the advanced outfitting system method, namely: General arrangement, construction profile, and equipment for a 2000 GT cargo passenger ship Data on shipbuilding facilities for 2000 GT passenger ship builders Stages of building a 2000 GT cargo passenger ship Data on the quantity of materials needed to build a 2000 GT cargo passenger ship.

Technical and Economical Data Analysis
After completing the data collection and management process, this study conducts technical and economic analyses.The scope of technical and economic analysis in this research typically involves examining various aspects related to the system.The technical analysis involves planning for the construction of a 2000 GT cargo passenger ship at shipyard X using the advanced outfitting system method.This analysis aims to assess the efficiency of the shipbuilding process when using this method.The first step is analyzing the design and functionality of the advanced outfitting system, including its components, features, and capabilities.Second, assessing how the advanced outfitting system integrates with other shipbuilding processes and systems, such as hull construction, electrical systems, and propulsion.Then, evaluating the impact of the advanced outfitting system on shipbuilding efficiency and productivity, including factors such as reduced assembly time, improved accuracy, and increased automation.
On the other hand, the economic analysis focuses on calculating the investment needed to provide additional shipyard facilities and the cost of building a 2000 GT passenger ship using the advanced outfitting system method [23], Finally, Cost- Benefit Analysis is conducted in assessing the economic viability of implementing the advanced outfitting system by comparing the costs associated with its implementation, operation, and maintenance against the potential benefits, such as increased productivity, reduced man-hours and labor costs [24], The results of this analysis provide insights into the feasibility of implementing this method in shipyards and its potential economic benefits.

Existing Condition of the Shipyard
The shipyard being studied is a ship construction company located in the city of Surabaya.The company has previously constructed a 2000 GT ship for the Ministry of Transportation, which is currently operated by PT.PELNI.However, the ship equipment installation method used by the company still relies on the on-board outfitting method.

Shipyard Layout
PT. X has a comprehensive set of main facilities, including an 8000 DWT graving dock, a launching way, and a sizable working area located to the north and south of the pond dock.The shipyard's layout is illustrated in Figure 3  Shipyard PT.X. has shipbuilding facilities consisting of the main office, material storage warehouse, plate workshop, and other workshops related to the process of working on ship equipment.The main facility as a place for an erection is carried out in a graving dock with a capacity of 8000 DWT.In addition, supporting facilities for ship construction, such as crawler cranes, have a lifting capacity of 150 tons.

Shipbuilding Method
The shipbuilding method that the company currently uses is the HBCM (Hull-Block-Construction-Method) which involves building the ship's hull and outfitting it while it is still in the dry dock.This method is commonly used in shipyards due to its efficiency and ability to reduce the time required to build a ship.However, the company still uses the traditional on-board outfitting method for the outfitting installation process.This method requires the ship to be launched first before the outfitting process can be started, which adds significant time to the shipbuilding process.The traditional ship outfitting installation process and the advanced outfitting method differ in several ways: a. Traditional Ship Outfitting Installation Process: The traditional ship outfitting installation process involves installing outfit systems and components on a structural block or outfit unit after the ship's hull has been erected [12], This means that the outfitting is done on-board the ship, typically in the later stages of construction.Some characteristics of the traditional outfitting process include: 1. Sequential Process: The outfitting is carried out in a sequential manner, where each outfit system or component is installed one after the other.
2. On-Board Installation: The outfitting is done on-board the ship, which requires access to the ship's interior spaces.
3. Longer Cycle Time: The traditional outfitting process often takes longer to complete due to the sequential nature of the installation.
4. Limited Flexibility: Any changes or modifications to the outfitting may be more challenging to implement once the ship's hull is erected.b.Advanced Outfitting Method: The advanced outfitting method, on the other hand, involves installing outfit systems and components on a structural block or outfit unit prior to shipboard erection [12], This means that the outfitting is done off-board the ship, typically in a separate facility or building berth.Some characteristics of the advanced outfitting method include: 1. Parallel Process: The outfitting is carried out in parallel with the construction of the ship's hull, allowing for concurrent work streams and reducing the overall construction time.2. Off-Board Installation: The outfitting is done off-board the ship, which provides better access to the outfitting areas and allows for more efficient installation.3. Shorter Cycle Time: The advanced outfitting method can significantly reduce the cycle time required to build the ship, as outfitting can be completed concurrently with hull construction [25], 4. Increased Flexibility: The advanced outfitting method allows for easier modifications or changes to the outfitting, as it is done prior to shipboard erection.
In summary, the advanced outfitting method offers advantages such as shorter construction time, increased flexibility, and improved efficiency compared to the traditional ship outfitting installation process.It allows for parallel work streams and reduces the dependency on sequential installation, resulting in a more streamlined and efficient shipbuilding process.

Technical Analysis of Implementing Advanced Outfitting System
After analyzing the existing shipyard condition and based on the theory from previous research, the next step is implementing the AOS theory in design and production stage.The design of the new yard layout comes after the production process has been done, the advanced outfitting method can be applied and supported by certain shipyard facilities such as graving dock, multi pontoon floating dock [26], outfitting workshop, etc.
Figure 1.Workflow for HBCM in shipbuilding Figure2.Efficiency improvement in advanced outfitting system Overall, the literature study played a critical role in achieving the research objectives by providing valuable insights and knowledge related to shipbuilding processes, outfitting installation, and shipyard development.By building on the existing literature and previous research, this study aimed to contribute to the advancement of the shipbuilding industry in Indonesia and to help address the challenges facing the industry in the present day.
Figure 3.The existing layout of Shipyard PT.X