Maximising Productivity, Efficiency, and Safety in Your Shipboard Repair Operations 102921
Maximising Productivity, Efficiency, and Safety in Your Shipboard Repair Operations 102921
Maximising Productivity, Efficiency, and Safety in Your Shipboard Repair Operations 102921
By Chris Teoh
Global Product Marketing Manager – Welding and Tools Solution
Industry 4.0
The Fourth Industrial Revolution, more commonly
referred to as Industry 4.0, is the automation of
traditional practices using modern innovative
technology. Over the years, digitally aware industries
such as automotive, aerospace and manufacturing, have
been leading the drive towards Industry 4.0. Companies
such as Bosch and Ford actively leverage the benefits of
innovation to increase productivity, reduce costs, and
improve efficiency.
- McKinsey
Let’s do a quick recap of how the sector is currently gripped by What does industry 4.0 mean for the maritime industry?
arguably the most turbulent period in its recent history.
Some players have been embracing the trend, with the advent of increasingly connected ports and
When COVID-19 first hit, it brought the industry to a virtual autonomous ships.5 However, the industry in general is slow to adopt this, and much more is needed.
standstill – shipping demand dropped, vessels were delayed, There is also a need to understand that automation does not only apply to ports. Pivoting to better
port entry was restricted, and more. According to the University solutions will enable ship operators to enjoy the benefits of increased efficiency, improved
of Oxford, the pandemic caused a 10% collapse in maritime productivity, reducing the risk of supply chain disruption and to personnel.
trade in the first eight months of 2020, creating losses of up to
$412 billion.1
The ability of shipping Leveraging on more efficient technology
As of July 2021, around 500,000 seafarers are either stranded
services to continue A key area where improvements can be made is in effective repair and maintenance.
on ships or unable to get on board the vessels, due to travel
undisrupted to transport
restrictions imposed worldwide. There are only a few signs of According to ResearchAndMarkets, the global ship repairing market is expected to grow from
food, energy and medical
the problem getting more manageable, which IMO has $30.16 billion in 2020 to $32.29 billion in 2021 at a compound annual growth rate (CAGR) of
supplies across the
described as a humanitarian, safety, and economic crisis.2 7.1%.6 Why so? The shipping industry is actively exploring ways to be better prepared for an
continents will play a critical
At a time when the industry was, and is still, running out of role in overcoming this endemic world, one where the world is slowly opening up but yet has to be flexible enough to
vessels, containers and resources, ship owners can’t afford any pandemic. Shipping adjust to unforeseen changes.
further potential disruptions to their shipping schedules. They companies will need to Shipboard welding and cutting are critical aspects of repair and maintenance programmes to
are under immense pressure to operate at high capacity and become agile and adaptable ensure vessels are operational. Today’s ship operators can choose from a wide range of welding
minimise time spent on ship repair and maintenance to avoid to this changing situation.”� and cutting equipment, and making the right selection is crucial in improving operations on
losing opportunities. board.
- PwC
2 3
Wire welding and plasma cutting
Which welding and cutting solutions – the ideal ways forward
are best for you? In many parts of the world, a growing number of ship operators are turning to wire
welding and plasma cutting as safer and more effective solutions to increase
productivity, with a lower total cost of ownership compared to other methods. While
neither process is new, their popularity has increased in recent years. Wire welding
currently represents over 45% of the total global welding consumables sold in the
welding industry over the past decade.
However, it can be difficult and costly to hire an experienced welder, especially when we are experiencing Increased productivity
a significant shortage of skilled welders. In addition to the fact that an average rate to hire a professional is By using wire spools, wire welding allows for continuous welding. This means it can deliver a
now at $15 to $20 per hour7, with limits on the number of crew members on board, finding someone with higher duty cycle (longer arc-on time) and faster travel speeds. In contrast, stick electrode
the skills to perform stick electrode welding or oxy-acetylene cutting accurately and safely can be a real welding requires stops at short intervals to de-slag, change electrodes and restart after each
challenge. 200 to 300mm of welding.
Stick electrode welding requires higher consumption of consumables over deposited weld metal due to Stick electrode welding allows only about 12 minutes of welding for every hour an arc is
generated. By comparison, wire welding can give up to 30 minutes of welding time per hour of
its lower efficiency. This method is restricted by the length of the electrodes, which are limited to 450mm
arc generation.
in length and are disposed of when they become reduced to an electrode stub. The process creates
wastage: about 10% of the electrode stub’s weight ends up as scrap or is unused (a rule of thumb is 1.5kg Meanwhile, plasma cutting uses compressed air and electricity readily available on board to
of electrode mass for every 1kg of weld metal). deliver a ‘cleaner’ cut compared to oxy-acetylene cutting. This process results in more
accurate, versatile, and higher cutting speeds and productivity for steel thicknesses up to
In terms of load, conventional welding and cutting equipment can be heavy to lift and move. The bulkiness 15mm.
poses a problem in the maintenance process, especially when it comes to areas that are difficult to
access.
Lower total cost of ownership (TCO)
While traditional welding and cutting processes are still commonplace, it’s time for ship operators to While the initial outlay for wire welding and plasma cutting equipment may be higher than
consider other methods that are more versatile and portable, ones that will maximise efficiency, conventional standard welding tools, their greater speed, efficiency, performance,
productivity, and safety – which are especially important in this new world we operate in. productivity and reduced waste mean lower overall project costs. In addition, as you would
only use what you need for wire welding, the likelihood of wastage is minimised significantly,
bringing a lower TCO for the project.
4 5
Unitor new generation
of welding and cutting
equipment
At Wilhelmsen, our Unitor New Generation
Welding and Cutting Equipment enables ship
operators to achieve all the benefits of wire
welding and plasma cutting while
complementing existing tools available on
board, providing greater flexibility and more
options.
There is no reason why the shipping industry can’t make good use of these benefits. It is
time for us to work towards better maintenance and repair programmes.
6 7
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References:
1 https://www.ox.ac.uk/news/2021-04-15-tracking-economic-impacts-covid-19-one-ship-time
2 https://www.imo.org/en/MediaCentre/HotTopics/Pages/FAQ-on-crew-changes-and-repatriation-of-seafarers.aspx
3 https://www.pwc.com/gr/en/industries/shipping-covid-19.html
4 https://www.mckinsey.com/business-functions/operations/our-insights/industry-40-reimagining-manufacturing-operations-after-covid-19
5 increasingly connected ports and the emergence of autonomous ships
6 https://www.researchandmarkets.com/reports/5323258/ship-repairing-global-market-report-2021-covid#src-pos-1
7 https://www.ziprecruiter.com/Salaries/Welder-Salary-per-Hour
8 http://www.haynesintl.com/alloys/fabrication-brochure/welding-and-joining/gas-metal-arc-welding-(gmaw-mig-)