boat yacht assembly

Boat building on the assembly line

Since its foundation, BAVARIA YACHTS has been known for its efficient production of yachts. Since September last year, BAVARIA has taken this philosophy of intelligent and effective organization to a new level: With a process that is also known in the industry as „value stream organization“, as Karsten Danker, division manager for the sailing yachts, explains.

Since 2000, BAVARIA YACHTS has been manufacturing on four production lines.

The boats come out of the lamination as more or less empty hulls, Danker explains. In the case of the sailing yachts, the engines and, above all, the „backbone“, a large, stable floor assembly that stiffens the boat and is the basis for further construction, which now takes place on the assembly lines, are already pre‐assembled. Likewise, the hulls and decks have already come through the gigantic CNC milling machine where all the hull openings have been cut: Board passages, windows and hatches.

Now each boat goes through further stations: Station One, wiring. Or station two, installation of the furniture modules, which are already delivered to the assembly line from the carpentry workshop, station three, lamination of the modules, and so on. Everything is thoroughly planned, like Swiss clockwork. Because planning is the key to success. Since all boats are only built to order and no two are exactly the same, the construction slots have to be allocated very carefully, depending on the order, the type of boat and the equipment. No easy task for Christina Issing, who is responsible for the processes within the company organization.

Until the wedding, when the deck is placed on the hull…

... all fittings and installations are done.

A well‐rehearsed team works at every station on the line. Worksheets that record the standard procedure ensure clarity and make it easier for new employees to get started. There are a total of four belts at BAVARIA YACHTS, with belt number four reserved for the „exotics“. These are the large motor yachts that don’t quite fit into series production, explains Andre Kirchner, head of the motorboat division.

The other belts each have about 30 stations, where each boat spends about a day before moving on to the next step. Sailing yachts from 45 to 57 feet are built on line 1, where each boat stays for 1.2 days per station and four boats leave the line every week. On belt 2 are the sailing yachts from 34 to 42 feet in length with 0.8 days per station, with six boats per week, and on belt 3 the motorboats of up to 40 feet in length spend 0.7 days per station with five boats per week. So on average it takes around six weeks for a boat to be finished on the line. In addition to that, there are also the lamination process beforehand and the final finishing before delivery that need to be considered as well. The "marriage", i.e. the joining of hull and deck, takes place shortly before station 13 and the keel assembly for the sailing yachts in the last third. Both are important milestones in the genesis of any boat.

The cabins come as finished modules...

... and are placed directly into the hull.

The advantages of this modern mode of production are convincing. Short distances, quick decisions within the team and a lean organization ensure the best efficiency with a high degree of cost‐effectiveness, which is above all to the customer’s advantage.

Thorough planning is required in advance, especially when introducing new boat types. Usually, the first one or two yachts are built as prototypes, if possible already within set times of the teams on the production line. This way, it is quickly determined whether assembly line production is possible, and whether the timing is right. In this phase, specialized industrial technicians make sure that the new developments are ready for production. Once this has been achieved, series production starts from hull three at the latest.

It’s a fascinating process in which everything interlocks smoothly. Or to put it another way: like a regatta crew in a race. Everyone has their own task when sailing and everyone knows what to do – then all manoeuvres succeed and a perfect result is guaranteed.

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Building a Yacht: Top Things to Know About the Yacht-building Process

Owning a yacht and having the freedom to explore our beautiful planet by boat is a dream shared by many. But building a yacht is a long and complex process. Should you be one of the fortunate ocean explorers who will get the opportunity to have your semi custom yacht built from scratch, you will undoubtedly require the services of an experienced and knowledgeable boat builder.

Knysna Yacht Company is a boutique yacht-building company based in the picturesque coastal town of Knysna on South Africa's world-famous Garden Route, and crafting beautiful, artisan-made semi custom yachts for clients around the globe is what we do best.

Having your yacht designed and built by a professional, acclaimed yacht builder like KYC will not only see you sailing off in a unique boat that was built to the highest standards. It will also ensure that you are a pivotal part of your yacht's design and construction process, right from the very outset.

While KYC builds your yacht, your input will not only be valued, it will be sought out and encouraged, with your particular tastes and preferences incorporated in every aspect of your boat's construction.

Continuous consultation and communication with the KYC team of expert yacht builders will see you taking to the seas in a boat that not only complements your personal style, but one that can truly be your home on the high seas.

Read on as we take a closer look at the various aspects of the semi custom yacht building process.

#1: What are the trademarks of a semi custom yacht?

When you first start to do your yacht-buying research, you'll no doubt come across various types of yachts available for purchase. Most of these will be standard, production yachts.

With a production yacht, what you see is truly what you get. There are virtually zero customizations that you can make to the layout or interior of an off-the-shelf production yacht,

A semi custom yacht, however, will afford you much more opportunity to add all those little touches that will make your boat a true extension of your personal style and tastes.

Even though semi custom yachts are built on a standard hull, when it comes to trims and finishes, appliances and the interior layout, that is all up to you.7The planning and design of a semi custom yacht can be compared to working with a home builder. Many larger home building companies have several base floor plans to select from, with the selection of cabinets, finishes, layout, and other details entirely up to the owner. It's the same with the design of a semi custom yacht.

#2: The advantages of a semi custom yacht

You might be wondering if a semi custom yacht is a better option than a standard production yacht. Buying a production yacht may save you money, but going for the cheapest option is not always the best choice.

There are clear advantages to having your own semi custom yacht built by professional yacht builders. One of those advantages is that you will personally be involved in the entire process of your yacht's construction.

A semi custom yacht build takes around 12 months to complete, allowing you ample time to really get stuck into the various design, building and finishing aspects of your boat.

In addition, you will almost certainly be cementing a long-lasting relationship with the dedicated team that is building your boat. Should you choose KYC as your yacht builder, this relationship will continue long after your boat's build is complete.

With a semi custom yacht, the price may be higher than what you'd pay for a standard production yacht (although the costs of KYC's boutique semi custom yachts compare very well with some new production yachts on the market).

But, if you choose to go for a semi custom yacht, you'll be getting much more than just a boat.

You'll be setting sail in a vessel you can take immense pride in, because you would have played a central role in crafting your boat to your exact tastes and specifications. If you select KYC as your yacht builder, you can also look forward to the many benefits of becoming a member of the KYC family of yacht owners.

This means you'll enjoy the support and expertise of an experienced team of yacht-building professionals for many years to come.

ContentImage_The advantages of a semi custom yacht

#3: Semi custom vs. production yacht

The advantages of having your own semi custom yacht built for you may be clear, but how do these boats compare to standard production yachts ?

Well, one major difference is alterations. When you're having a semi custom yacht built, you can make changes as you go. With a standard production yacht, you are buying the boat pre-made. Alterations to a production yacht after the fact can cost a lot of money, and may not be that simple – or safe – to execute.

Why would altering a production yacht post-sale be a safety risk? A production yacht's design and aesthetics may hide pre-existing flaws in the boat's construction. In itself, this could already pose potential safety risks. Making further changes or additions to a yacht that may already contain pre-existing design flaws would not be a wise course of action, and could be very dangerous indeed.

If you're involved in every step of the build of your semi custom yacht, you will have the opportunity to closely inspect your boat at every stage of its construction. This is a valuable advantage that could potentially allow you to avoid safety issues and layout problems relating to your boat.

#4: Building a semi custom yacht

If you choose to have yacht builders build your semi custom yacht from scratch, you'll be involved in every step of the process. For this reason, it will be in your interest to know as much as possible about your boat's building process.

So, what is the actual process of building a semi custom yacht?

ContentImage_Building-a-semi-custom-yacht

Building the hull

The first stage of the yacht-building process involves the "bones" of your yacht. During this stage, your yacht's hull and superstructure are made.

Unless they have commissioned a completely custom yacht to be built from the ground up, boat owners typically aren't involved in the selection of their boat's hull. However, it is important to know what this process involves.

Constructing a boat's hull is a process that takes four to six months to complete and takes place in a boat builder's aluminium or steel workshop. A steel yacht hull is extremely durable, but it will add a lot of weight to the overall weight of your boat.

Steel is one of the most common hull-construction materials, as it can be constructed and maintained with low technology, and at a relatively low cost.

Aluminium or alloy hulls are one of the better options available for hull construction, as they are so much lighter. These hulls offer the durability and longevity of steel hulls, but add only a fraction of the weight of a steel hull to your yacht.

After your yacht's hull is complete, it will have to go through a rinsing and priming process before your boat will be ready for the next step in its construction: finishing.

Finishing the yacht

Once your yacht's hull is complete, the second stage of your yacht's build can commence. This is the part where you'll start to see your boat "come to life".

The finishing process of your yacht is made up of several stages, including:

Installing the yacht systems
Interior and exterior carpentry
Insulating the yacht
Varnishing the yacht interior
Spray painting the hull/superstructure
Installing the mast

Semi custom yachts are beautiful machines. And, under such a boat's surface, a lot goes on to keep that beautiful machine moving and functioning as a self-contained living unit on the water. A large network of wiring and systems will be expertly installed to keep your yacht running smoothly and safely.

Yacht systems

It takes several systems for your new boat to run, including a navigation system, anchoring system, electrical system, propulsion system, air conditioning system, water systems, and more.

Each of your yacht's systems requires an expert team possessing the necessary knowledge and expertise to install it correctly and efficiently. Some people set sail with a yacht engineer as part of their crew team, to keep everything running smoothly onboard. However, KYC offers all new Knysna yacht owners a complimentary, 2-week training period during which they are shown and taught everything they need to know in order to maintain their yacht's systems themselves.

Gel coating & interior and exterior carpentry

A yacht's gel-coating process is done with a resin that bonds with the fibreglass surfaces throughout your boat. Gel coating ensures no leaks and cracks on a yacht's surface, but it can also be applied to add more colour to your boat.

Since most yacht hulls and exteriors are finished in fibreglass, gel coating becomes an extremely important part of the yacht-building process.

After gel coating, the interior of the yacht receives a protective varnish. The yacht exterior is also gel-coated and waterproofed to prevent leaks and ensure the boat is completely sealed.

Carpentry is also an essential component of your new yacht. Marine carpentry experts are required for both the interior carpentry (think bathroom cabinets, kitchen counters and seating), as well as the decks and other carpentry aspects on the boat's exterior.

ContentImages_Gel-coating-&-interior-and-exterior-carpentry

Yacht builders and their teams

If you select to have your yacht built by a big yacht-building company, a project manager will be appointed to oversee your yacht's construction, making sure the entire process runs smoothly. Project managers are typically the face of a boat-building company, and clients will deal with their boat's project manager as their point of contact throughout their yacht's construction process.

Underneath the project manager, you'll likely have a team of engineers, systems installers, artisans, an interior designer, and a few legal team members.

Should you choose to have your semi custom yacht built by KYC, you will be dealing directly with KYC’s owners. You will also have access to your under-construction yacht at all times, ensuring that the lines of communication remain open and that your needs are being met.

ContentImages_Yacht-builders-and-their-teams

Selecting the right yacht builder

It's essential to choose the yacht builder best suited for your particular project. There are several questions you should ask yourself before selecting a company to build your yacht.

First, you will have to decide on the type of vessel you want. Many boat builders specialise in certain types of boats. Knowing what type of boat you want will be the first step toward deciding which yacht builder is right for you.

Next, you'll want to figure out how far you'll typically be sailing. This is known as your yacht's range. If you're only planning on doing shorter sailing trips, that will require a specific type of boat. If you want to sail out on the ocean for weeks or months at a time, that will require a different kind of boat entirely.

Finally, ask yourself how long you're willing to wait for your new boat . This wait is known as your lead time. If you're okay with waiting 2-4 years for your yacht to be built, then you can consider selecting a fully custom yacht.

Semi custom yachts, including KYC’s artisan-built Knysna 500SE and Knysna 550 yachts can be completed much faster. This will vary from builder to builder, but most semi custom yachts have a much shorter lead time than a fully custom boat that is built from scratch.

Financing a semi custom yacht

Financing a boat that is yet to be built is notoriously difficult, with most banks and financial institutions only willing to provide loans for completed boats. At KYC, we offer clients a Yacht Construction Financing Option, allowing them full flexibility to pay off building costs over the boat's complete building timeframe.

Become a yacht owner faster

Let us answer your yacht-building questions!

Read our blog article on yacht financing and learn more about KYC's unique Yacht Construction Financing Option.

Let us answer your yacht-building questions

There are lots of points to consider when you're thinking of having a boat built.

Our team of KYC yacht-building experts will help you navigate the yacht-building process to ensure that your journey towards ultimate freedom is smooth sailing every step of the way.

Don't hesitate to send us a message at [email protected] and let us know how we can help.

Yacht Maintenance - Top Tips for Protecting Your Investment

Essential things to know about boat insurance, top things to know about yacht solar power, get all the latest to your inbox, discovery awaits.

BOAT CONSTRUCTION TECHNIQUES : PRODUCTION LINE VS CUSTOM BUILDS

Boat construction has come a long way over the years, with various techniques and materials being used to create vessels of different shapes, sizes, and purposes. Two primary methods of boat construction are production lines and custom builds. In this article, we will compare these two techniques and discuss the advantages and disadvantages of each, as well as the factors to consider when choosing the right construction method for your boat project.

PRODUCTION LINE CONSTRUCTION METHOD

1. Efficiency and Affordability

Production line boat construction, also known as mass production, involves manufacturing multiple boats of the same design using standardized molds and assembly line techniques. This method has revolutionized the boat-building industry, making it possible to produce boats more efficiently and at a lower cost. The economies of scale achieved through mass production result in more affordable boats for the consumer market.

2. Consistency and Quality Control

One of the main advantages of production line construction is the consistency in design and build quality. With standardized molds and processes, each boat produced is nearly identical to the others, ensuring a high level of quality control. Moreover, production line facilities often use advanced technologies and equipment that further enhance the precision and quality of the boats being built.

3. Limited Customization Options

While production line boat construction offers efficiency and affordability, it also limits customization options for the buyer. Due to the standardized processes, there is little room for personalized alterations or unique design elements in production line boats. These boats are typically built to cater to a broader market, making them more suitable for those looking for a tried-and-tested design rather than a one-of-a-kind vessel.

CUSTOM BOAT BUILDS

1. Personalization and Unique Design

Custom boat builds offer a level of personalization that production line construction cannot match. With a custom build, the boat owner can work closely with a boat builder or designer to create a vessel tailored to their specific needs, preferences, and style. Custom boats often feature unique design elements, high-quality materials, and innovative technologies that set them apart from mass-produced vessels.

2. Craftsmanship and Attention to Detail

Custom-built boats often showcase superior craftsmanship and attention to detail compared to production line boats. Skilled boat builders take the time to handcraft each component, ensuring that every aspect of the boat is built to the highest standards. This results in a higher-quality, more durable vessel that can better withstand the rigors of the marine environment.

3. Higher Cost and Longer Build Time

One of the main drawbacks of custom boat construction is the higher cost and longer build time. Custom boats are labor-intensive and require more time and resources to complete compared to mass-produced vessels. Additionally, custom builds often use premium materials, which can further drive up the cost. However, for many boat enthusiasts, the investment in a one-of-a-kind vessel is well worth the added expense.

Choosing the Right Boat Construction Method

When deciding between production line and custom boat construction, several factors come into play:

Budget: Production line boats are generally more affordable, while custom builds can be more expensive due to the personalized design and craftsmanship involved.

Purpose: Consider the intended use of the boat, whether it’s for leisure, fishing, or racing, and determine which construction method best suits your needs.

Customization: If having a unique vessel with personalized design elements is important, a custom build may be the better choice. However, if you prefer a more standardized, proven design, a production line boat could be the ideal option.

Build Time: Production line boats are typically completed faster than custom builds, so consider the timeline you have in mind for your boat project.

Both production line and custom boat construction methods have their merits, with each catering to different preferences and budgets.

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