Shipyard layout simulation using ARENA: a case study

Abstract

This study models and compares two layouts of the same shipyard system — existing and optimised — using Arena Discrete Event Simulation (Arena DES). Production data from a ship built at a private shipyard in Yalova, Turkey, were analysed to evaluate the effect of layout optimisation on production time. The existing layout has a total transfer distance of 4899 meters, while the optimised layout reduces it to 3837 metres. The results show that Transfer Time constitutes 23.89-31.74% of the Total Process Time in the existing layout and 21.20–28.92% in the optimised layout. Layout optimisation decreases Transfer Time by 12.17–15.71% and Total Process Time by 2.55–4.42%. Model validation involved comparing simulated and actual shipyard data, confirming entity counts and department utilisation. Overall, the study demonstrates that excessive material transfer can be minimised through layout optimisation, providing a validated, data-driven framework linking simulation modelling with industrial shipyard practice.