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By Binod – Estimation Engineer | Ship Repair & Retrofit Specialist
Improving ship repair operations in a shipyard is no longer just about welding and steel renewal. In today’s competitive and environmentally regulated market, success depends on precision estimation, digital integration, lean practices, and a skilled workforce. With over 15 years of global experience across Singapore, the UAE, and Saudi Arabia, I’ve seen firsthand how these elements can transform shipyard performance.
The first and most important step is improving the planning and estimation process. A well-structured scope of work using Work Breakdown Structures (WBS) allows each task—be it hull repairs, machinery overhauls, or electrical system upgrades—to be estimated accurately. Leveraging historical job data and applying recognized frameworks such as GAO/NAVSEA or AACEI ensures accurate cost forecasting, minimizes change orders, and gives confidence to both clients and yard management. By integrating contingency planning early, we can reduce cost overruns and unexpected delays.
Embracing modern technology is equally critical. Many successful yards are investing in automated welding machines, robotic inspections, and AR-based guided repair systems. These tools not only reduce errors and improve safety, but also shorten repair cycles. Internet of Things (IoT) devices and digital twin systems allow real-time monitoring of vessel systems, which helps plan condition-based maintenance instead of reactive work. For estimation engineers, this means more accurate timelines and better control over resource allocation.
Continuous improvement through lean practices can also deliver significant gains. Regular audits of workspaces and logistics routes can uncover inefficiencies in material flow or manpower deployment. Implementing 5S systems and lessons-learned reviews after each project helps reduce waste, improve safety, and ensure better outcomes for the next job. Involving cross-functional teams—including design, procurement, and production—creates a collaborative environment that prevents last-minute surprises.
Asset management is another crucial area for long-term improvement. Aligning the shipyard’s operations with ISO 55000 asset strategies ensures proactive maintenance of docks, cranes, and machinery. When the yard’s own assets are reliable, project execution becomes more predictable. Alongside this, implementing environmental management systems such as ISO 14001 helps meet growing regulatory and client demands for sustainable operations.
A key factor often overlooked is workforce development. As senior technicians retire and younger workers come onboard, there’s a need to preserve practical knowledge. Recording procedures, creating step-by-step guides, and cross-training technicians ensures continuity. Also, empowering teams with clear KPIs and visual dashboards creates a performance-driven culture where progress is measurable and celebrated.
To stay competitive, shipyards must also benchmark themselves globally. Yards like those in South Korea, India, and Greece have raised the bar with modern infrastructure and operational discipline. Building partnerships or knowledge-sharing agreements with such facilities can bring valuable insights and open doors for international collaboration. These relationships also offer flexibility when local capacity is limited or specialized expertise is required.
Finally, sustainability is no longer optional. Shipowners are under pressure to reduce emissions and meet IMO compliance standards. Offering green repair solutions—like scrubber installations, ballast water treatment systems, or non-toxic coatings—not only positions the yard as a future-ready service provider, but also opens new revenue streams. At the same time, implementing eco-friendly practices within the yard—such as energy-efficient lighting, waste segregation, and noise reduction—enhances the shipyard’s public image and helps attract ESG-conscious clients.
In conclusion, improving ship repair business in the shipyard requires a multi-dimensional approach. By combining accurate estimation, smart technologies, lean practices, skilled teams, sustainable operations, and global benchmarking, any shipyard can increase profitability, reduce risks, and build long-term client trust. I believe every yard, big or small, has the potential to grow stronger if these principles are consistently applied