When hulls and decks are finished, the milling and drilling for the installation of hatches, throughhull-fittings etc. is the next step in the production line. In cooperation with an engineering company the shipyard has developped highly specialised computer-controlle CNC rotary grinders with multi-fold retooling for this job. The deck layout of each yacht type, as well as the whole pattern for standard and optional equipment, is stored by CAD/CAM. Laser technique enables the robot to quickly scan and check out the yacht in the work station and to "know" which model it is and which pattern it has to follow.
Photo: The CNC device starts to mill the first cutouts into the deck .
Although several hundred single operations are necessary, the whole job is finished within one hour and all openings drilled - absolutely flawless and in no time, with a tolerance of less than one millimeter. This accurateness is crucial for the later tightness of the boat.
One huge fabrication hall is reserved for the carpentry workshop. Here the furniture and wooden parts of a Bavaria Yacht are produced. Raw plantatation wood enters the workshop and will leave it as prefabricated, whole furniture modules ready to be mounted on the yachts. Again all processing is highly automated - CNC-devices and robots fabricate all furniture accurate to measurement (to the millimeter). An automatic varnishing-line ensures the multi-layered high quality coating of all wooden parts. Every piece is sprayed evenly with a two component varnish with UV-drying between layers until the gloss and the thickness of the coating satisfies the high demands of the final quality control.
With the mounting of all parts the work on the conveyor belt really begins. Due to different production times, small and larger yachts are built on different lines to ensure a good work flow at all times. The procedures along the line are scheduled down to the smallest detail. The teak is bonded to the deck in a vacuum process, after that all fittings, hatches, winches etc. are completely mounted to the decks. Parallel to that, on other conveyor lines, the hulls are equipped. The electric wiring, tanks, engine and furniture modules are installed. When everything is in place, it's time for the "big wedding" and the deck will be fitted on the hull.
Photo: "The big wedding" - union of deck and hull
To minimise the height through the production
process and simplify transport along the assembly line, keel and
rudder are not mounted to the yacht until the very end. Laser
technique ensures the correct enlignment before the yacht is
lowered on its keel.
After cleaning, sealing and the final quality control the vessel leaves the shipyard. Freightforwarders specialised in yacht transport deliver the boat to its port of destination. Very often the last bit of the journey is across the sea, e. g. those boats going to Majorca are rigged on the Spanish mainland and come sailing across to us.
Photo: The yacht is carefully lowered to its keel