Oceana Shipyard Transforms Shipbuilding Efficiency with Integrated Approach
In the competitive world of shipbuilding, effective cost management is crucial. A significant portion of a shipbuilding budget—60-70%—is allocated to material costs, while engineering accounts for about 5% and labor takes up 25-35%. To control these costs, shipbuilders must master material flow throughout the project lifecycle. However, traditional shipyards often face challenges due to fragmented material flow, siloed departments, and limited visibility. These issues can lead to inefficiencies, miscommunication, and costly delays.
Oceana, a Brazil-based shipyard founded in 2013, has adopted an innovative approach to address these challenges. By implementing AVEVA™ Enterprise Resource Management, Oceana has unified its departments and streamlined operations across the entire project lifecycle. This integration has proven essential in enhancing collaboration, improving material management, and increasing overall visibility.
Addressing Fragmentation and Inefficiencies
One of the primary obstacles in traditional shipbuilding is the lack of integration between departments. Teams often re-enter the same data into multiple systems, resulting in unreliable information and wasted time. Oceana has tackled this issue by creating a shared data environment where all departments—engineering, procurement, planning, and construction—work from a single source of truth. This integration allows for real-time updates and ensures that all teams are aligned, reducing the risk of errors and miscommunication.
Additionally, Oceana’s new system enhances material management. By connecting engineering outputs directly to procurement and warehouse systems, the shipyard can accurately forecast material needs, avoid double ordering, and ensure timely availability of materials. The dedicated material management tool within AVEVA supports the entire flow of materials, from budgeting to procurement and warehousing, thereby minimizing the risk of overspending and stock discrepancies.
Improving Control and Visibility for Better Outcomes
The lack of control and visibility in traditional shipbuilding processes can lead to outdated designs and incomplete bills of materials (BOMs). Oceana’s integrated approach addresses this by providing real-time visibility into design changes and project progress. Construction crews now work from up-to-date designs, significantly reducing the likelihood of installation errors and rework.
With enhanced visibility, Oceana can release work orders closer to execution dates, maximizing agility and flexibility. This capability allows the shipyard to navigate disruptions effectively while maintaining accuracy and coordination. Furthermore, Oceana tracks work hours against specific work orders in real time, enabling planners to monitor progress and make necessary adjustments promptly.
As a result of these improvements, Oceana has achieved industry-leading production times, delivering new builds on schedule or even ahead of schedule. An independent study highlighted Oceana’s success, attributing it to their integrated approach and the AVEVA solutions that facilitated this transformation. Oceana’s experience serves as a valuable lesson for the shipbuilding industry, emphasizing that integration is not just about technology; it is about fostering collaboration, enhancing visibility, and leveraging shared data to achieve common goals.
