advanced outfitting

ADVANCED OUTFITTING Presented by:- Adarsh E.K. Akhil Anant Chandan Kumar Harikrishnan

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Page 1: Advanced Outfitting


Presented by:-Adarsh E.K.Akhil Anant

Chandan KumarHarikrishnan

Page 2: Advanced Outfitting


Introduction to Outfitting

Zonal Design Work

Introduction to Advanced Outfitting

Types of Advanced Outfits

Benefits & Impact of Advanced Outfitting on Shipbuilding Industry


Page 3: Advanced Outfitting



Structural Component


Ship Construction

Structural Units Assembly Blocks

Rings(Grand Blocks)Ship

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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


Electrical (power distribution))


Painting & Insulation




Page 5: Advanced Outfitting

Outfitting (Stages)• Some outfitting must be done during the building• of the structural units or blocks since it would be • difficult and expensive later in const. process.• e.g. Pipe-Work in Double Bottom sections

• Some outfitting must be done during the building• of the structural units or blocks since it would be • difficult and expensive later in const. process.• e.g. Pipe-Work in Double Bottom sections

• Pre-Outfitting

Advanced Outfitting

Performing outfitting task early in the shipconstruction process i.e. at unit, block or grand block stages


Occurs at the assembled stage and require worksto move to dry dock, slipway or land-level facility bringing with them materials & equipments

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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

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Difficulty of the task2

Excess of Man-hours required 3

Obstructions in outfitting process4

Reduction in productivity of the shipyard5

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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.

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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

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Advanced Outfitting

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


Organization of information and materials to a plan that applies labor and facilities to integrate ship’s structure and outfit materials at the earliest and most cost effective stage of the construction process.





Page 11: Advanced Outfitting

Goals of Advanced Outfitting

Improved quality, productivity and worker safety

Improved use of cranes

Avoid interference between trades

Simplify outfit planning

Reduce outfitting time

Minimize on board outfitting

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1.On-Unit Outfitting

Enhances safety

Reduces both required man-hours and durations which would otherwise be allocated on outfitting on-block and


20% of the items are fitted in this stage


Page 13: Advanced Outfitting

An Example

Seawater Service Pump And An Air-conditioning Water Pump

Page 14: Advanced Outfitting

Steps• Shown in previous slide is a machinery unit which will

contain both a Seawater Service Pump and an Air-Conditioning 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.

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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

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A pipe piece is being lifted by the shop's bridge crane for bolting to the Seawater Service Pump

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A second worker temporarily assists by guiding a strainer to its final position while the gasket and a few bolts are secured

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Pipe piece supports are being fitted

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The completed unit is being transported for fitting on-block

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2.On-Block Outfitting

On-Block outfitting purposes refer to a rather flexible relationship between block and zone.

The zone applies to a region being outfitted. Following block turnover, the

fitting arrangement on deck is another zone

50% of the items are fitted in this stage


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On Block Advanced Outfitting

Advanced Outfitted

Grand Block

Modular Engine Room


Page 22: Advanced Outfitting


forecastle upside down forecastle deck right upside up

side shell and engine room flat upside down

aside shell and engine room flat right side up

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• 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.

Page 24: Advanced Outfitting

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 encompasses everything to be fitted to the tank top.

• The primary goals of this manufacturing level are to outfit ceilings and double bottoms when blocks can be manipulated to provide ideal access.

Page 25: Advanced Outfitting

Outfit Units

Engine room tank top unit

Engine room tank top componentsfitted on-block

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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

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

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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:

Hull large quantity / small quantity


Machinery large quantity / small quantity

Superstructure large quantity/ small quantity

2 3

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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.

Page 29: Advanced Outfitting

3.On-Board Outfitting

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


Page 30: Advanced Outfitting

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

Page 31: Advanced Outfitting

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

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Problems Faced

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• 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.

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Fitting work of the identical problem classification shown in is being performed on unit in a shop the smart way.

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• 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.

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• 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.

• 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.

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Advanced Outfitting Practices-A Comparison

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

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

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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

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20% Advanced Outfitting

80% conventional Outfitting

80% Advanced Outfitting

20% conventional Outfitting

50% Advanced Outfitting

50% conventional Outfitting

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• 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

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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 is getting popular esp. accommodation area.

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

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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?

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Thank You !!