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Dry-Docking Excellence using Six Sigma

approach.
Objectives

Approach

Standardize the dry-docking


process in terms of
procedures, job roles and
responsibilities, team.
Reduce unplanned and growth
work.
Standardize the dry-docking
specifications
Improve reliability and
maintenance management
strategies.
Implement a detailed drydocking tool and integrate
with yards, suppliers and
internal stakeholders.
Dry-dock project management
system upgrade.
Define maintenance
procedures in detail.
Standardize the invoicing
process in agreement with
yards. Define job specific
prices as per previous data
available.
Improve accuracy and on time
performance.
Creating a benchmark for drydocking process and evaluate
yards
Broader utilization of condition
assessment devices.
Create a system to share
lessons learned from past drydock projects.

Identify best practices for Predocking inspections and


prepare a detailed job scope
which should be carried out
along with pre-docking
inspections, such as UTM,
Thermography etc.
Carry out pre-study on the
existing dry-docking process
and identify the good
practices and the flaws from
TO, yards, vendors and service
companies
Prepare a list of standard jobs
and procedures that must be
carried out in a dry-dock to
eliminate maintenance issues
later.
Create machinery specific
instructions for repairs and
identify standard procedures
for the same.
Management of vendors and
service engineers and rating
their service.
Discussion with yard to access
their Standard operating
procedures and identify
improvements to suit Maersk
requirements.
Development of a dry-docking
software, which integrates
with yards, and all internal
stake holders. This tool should

Deliverables

Detailed procedures for predocking inspections


identifying jobs to be carried
out and vendors being used.
Checklist and standard
procedures pertaining to jobs
that must be carried out in
dock.
Detailed maintenance
procedures and service
engineers required for the
same.
Identifying the team, roles
and responsibilities mapping
for ship staff and shore
support.
Detailed dry-docking
software for record keeping,
analysis and comparison and
information management.
Development of KPIs and
benchmark studies.

KPIs and Benchmark

Estimated cost to Actual


Cost.
Estimated duration to actual
duration.
No of additional unplanned
jobs.
No of incomplete jobs.
No of Near misses and page 1
accidents

Time and Cost Effeciency


Dry-Docking Cost Comparison
120.00%
100.00%

Estimated 1015% savings in


docking cost is
the target
range.

80.00%

60.00%

Benefits

40.00%

Better Dry-docking management


Continuously improved
specifications.
Better pre-docking preparations.
Improved relations with
shipyards.

25 40 Million USD
savings.

20.00%
0.00%
Estimated Cost

Actual Cost

Better Manpower utilization.


Contributes to maintenance excellence project by
lesser downtime of machinery.
Critical failures due to missed out work in drydock reduce.
Lesser disputes with invoices.
Better time management and accuracy in dock.
Better record keeping for analysis and
comparison.
Transparency in the process and better
information availability for all stake holders.