Adjacency-Based Facility Layout Optimization for Shipyards: A Case Study

Abstract

A shipyard located in Yalova, Turkey, with an annual processing capacity of 50,000 tons of steel, is studied to improve the layout to increase the production efficiency. The material and personnel traffic inside the shipyard is complex, considering the nature of the shipyards. Therefore, an adjacency-based optimization procedure has been adopted in this study since this procedure allows quantitative evaluation of these aspects. Systematic layout planning (SLP) and graph-theoretical approach were used to generate 12 alternative layouts. Then, the best alternative layout was selected using the efficiency rate method. This study demonstrates the use of SLP and graphic-theoretical approach in a maritime context and utilizes the efficiency rate method to compare the alternative layouts, which are between 48.91% and 73.91% efficiencies, respectively. This study is a novel contribution to the literature in terms of demonstrating this methodology for shipbuilding applications, and practical applications for the industry can improve the industry to improve the efficiency of their operations. In parallel with the increase in global economic growth and technological developments, new ships are needed for marine transportation, energy, security, fishing, etc. This need triggers a globally competitive environment for the production of vessels in a cheap and efficient manner, which directly affects the shipbuilding industry and shipyards (Odabasi 1993). The alignment of the production departments in the shipyard is critical for productivity. The shipyard should be optimized and designed as an efficient system to minimize unnecessary material and personnel traffic. On the other hand, the majority of shipyards are poorly designed. Facility layout deals with the placement of the production departments based on their relative relationship, and facility layout design aims to streamline the workflow and increase productivity (Muther & Hales 2015). Dixit et al. (2020) describe the facility layout as a physical arrangement of departments with a focus on workflow across the system to achieve highest operational efficiency at the lowest cost. Facilities layout is fundamental to shipyard efficiency. To address this gap in the literature, this paper examines the application of systematic layout planning (SLP) and graph-theoretical approach to the optimization of a specific facility layout.