How to prevent failures and non-conformities

1. How to prevent failures and non-conformities Overflate 08 Dr M Raouf Kattan Managing Director Safinah Ltd www.safinah.co.uk

2. Why coatings now? A ship is a collection of engineering systems Process of coatings remained static – non-engineered Other systems moved forward by better design/engineering Coatings increasingly the limiting factor in maintenance intervals. Not well understood as a discipline Low level of engineering know how to solve the problems.

3. Scope for cost reduction Procurement (e.g.) Design – use of materials Operation – reduce manning Operation - Improve reliability Operation - Fuel economy - improved ship operating profiles Extended docking interval - Improved coatings Improved coating management – Less maintenance If these are not enough then, if you do it right: – Fewer consultants and lawyers!

4. Actual life/Expected Life Performance Target Life Actual Life Time in years

5. If it goes wrong • All you have are good people doing their best with the tools they have to put it right. • These people can • Be Brave • Innovate • Improvise • They just want to do their best with what they have.

6. Brave

7. Innovative

8. Improvise

9. So if it is not the people? • Then it is the management

10. Costs - magnitude of the problem Technologyimprovement actual work content Process improvement Design Technology Management Skill base Resources Time

11. Costs – Reduced – Predictability improved Continuous Improvement Technology improvement actual work content Process improvement Resources Time

12. So how to stop the failures? • Design and material selection • Process understanding • Coating strategy • Specification • Recording/retrieval and analysis • Through life maintenance • Engineer the solution – do not leave it to chance

13. Potential return on investment Safinah study on major Naval Fleet • For every £1per sqm spent getting the design and engineering right – save £450 per sqm over life of vessel (20 years) Cost influence Design Construct Operate Contract Build Delivery In service Time

14. Typical symptoms

15. Route to cost control First step - Control costs Need data Need understanding Need to prioritise Need to engineer a solution at New Build Need to engineer a solution through life Second step - Break through to lower costs Adopt new designs, New technologies, New systems, Learn new skills.

16. Audit and benchmarking Getting the perfect finish should not be left to chance. • Coating remains a bottleneck process and is unpredictable. • The conduct of a coating activity review is the first step to improve coating activity performance • Action plan for improvement

17. Coating Strategy Productivity by design • Integrating the coating activities into the shipyard processes. • Integration of facilities and processes to improve productivity and quality • Reducing total coating man-hours and costs.

18. Functional Paint Specification An engineered solution to coatings • Matching the coating selection to the needs of yard processes and strategy. • Matching the coating selection to the owner requirements • Maximize yard productivity • Improve through life performance of coatings • Improve the supplier selection process

19. Data management Remote database Electronic data gathering Local PC Coating Technical File Reference drwgs Standard documents

20. Predictability • The key is to improve predictability • Will not eliminate all uncertainty • Bring control • Reduce failures

21. Outcomes • Yard audit regularly reveals significant areas of cost savings • Paint specifications have generated in excess of 30% of total paint and application costs on some vessels • Paperless QA estimated to save 25% time for administrative work at current load (pre IMO PSPC).

22. Engineering systems • Simply need to apply similar disciplines to engineering the coating system as you would to other systems.