On November 5, at the panel factory of HD Hyundai Heavy Industries in Ulsan, a robotic arm descended onto a massive steel plate, igniting a series of dazzling sparks as it began welding. The robot seamlessly continued its work along the seams of the steel plate, while nearby workers monitored its performance and prepared for subsequent tasks. Just a few years ago, the shipyard relied heavily on skilled workers, but it has now transformed into a smart shipyard where humans and robots operate as a 'one team.'
The first sight upon entering was a welding robot suspended from a ceiling crane. This robot confirmed the welding position based on the ship block information input by the operator and completed its task efficiently.
HD Hyundai Heavy Industries has deployed 12 such robots in its panel factory, with one operator able to manage up to four robots. The company reports that productivity has increased more than threefold compared to traditional manual and carriage welding methods.
In another area of the factory, a 'collaborative robot' caught attention as it was manually moved by an operator. In spaces difficult for crane-type robots to access, the operator selected the welding sequence and conditions via software, prompting the robot arm to begin its work.
The welding speed, current, and thickness were adjusted according to pre-set conditions established by in-house engineers. The operator focused solely on ensuring the robot moved smoothly while preparing for the next task.
A representative from HD Hyundai Heavy Industries stated, "Using collaborative robots can increase productivity by about 40% compared to traditional manual and carriage welding methods. It also helps maintain consistent welding quality, reducing rework and enhancing overall process efficiency."
HD Hyundai Heavy Industries' use of robots extends beyond welding. In the production process of 'lugs,' temporary connectors used to lift large blocks during shipbuilding, an autonomous manufacturing system capable of operating 24 hours a day has been implemented. This system automates the entire production line from cutting to assembly and welding based on design data.
Previously, multiple workers were involved in a process that produced approximately 1,800 tons annually. The transition to an unmanned production system has increased output while saving about 500 million won annually in costs for that process.
Stepping outside the factory, the sight of steel plates being welded transformed into massive ships at the shipyard. Large ship blocks were stacked throughout the yard, and yellow special transport vehicles were carrying the heavy blocks.
The third dock, which was toured, measures 672 meters in length and 92 meters in width, equivalent to nine soccer fields. Here, five vessels, including liquefied natural gas (LNG) carriers, liquefied petroleum gas (LPG) carriers, and ammonia carriers, were being constructed simultaneously.
Thanks to a booming shipbuilding industry, HD Hyundai Heavy Industries delivered 88 vessels last year and is set to deliver 106 vessels this year. As the volume of construction increases, the role of robots is expanding throughout the shipyard. The company aims to enhance work speed and efficiency by combining the precision of robots with the skills of experienced workers.
Shin Sang-beom, Executive Director of Automation Innovation at HD Hyundai Heavy Industries, emphasized in a recent interview, "The primary goal of deploying robots is not to replace workers but to enable new employees to work more safely and efficiently."
Workers' perceptions on-site are also changing. Initially, there were concerns about job displacement and the inconvenience of moving equipment, but recently, as workloads have decreased and welding quality has become more consistent, there has been a growing demand for more robots.
HD Hyundai Heavy Industries plans to further expand its robot deployment, aiming to increase productivity by 30% and reduce costs by 10% by 2030, maintaining the current workforce level. The number of robots, currently around 260, is expected to rise to approximately 3,000 by 2030. The payback period for investments in robot deployment is estimated at about two to three years. In the long term, the company aims to establish an autonomous manufacturing system that connects the entire shipyard as a single system, beyond just automating individual processes.
Advancing robot technology is also seen as a crucial task in competing with China's shipbuilding industry. China is expanding its robot adoption and production facility investments with government support, closing the gap with South Korea's shipbuilding sector.
Shin noted, "In terms of the number of general program-based automation robots, China is far ahead. However, the key is not just in standardized tasks but in finding automation solutions for non-standard tasks."
He added, "We will enhance productivity by integrating our accumulated shipbuilding technology and block deformation prediction capabilities with AI and robot technology, securing differentiated technological competitiveness against China."
* This article has been translated by AI.
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