ENHANCING OPERATIONAL EFFICIENCY THROUGH CAPACITY STUDIES

BlastOne’s Capacity Studies are designed to systematically analyze and improve the efficiency of blasting and painting operations. By assessing workflows and identifying bottlenecks, these studies provide practical solutions aimed at enhancing productivity and reducing costs.

Key Components of Capacity Studies:

• • • Inefficient Blast and Paint Operations

      Blast and paint make up 53% of maintenance schedules but only account for 20% of the total cost. Delays in this critical-path process cascade across the entire project, causing significant disruptions.

  • • Aging Infrastructure and Equipment

      Many naval shipyards still reply on 40+ year old equipment and facilities, leading to inefficiencies, longer reproduction cycles, and frequent breakdowns.

  • • Limited Capacity and Resource Constraints

      With a limited number of shipyards handling a growing workload, maintenance backlogs occur, slowing progress and compounding delays.

• • Tight Deadlines

    Minimized Downtime: Ships are docked for limited periods, and every hour out of service results in financial losses. Rust removal, blasting, recoating, and floating must be completed efficiently to meet schedules.
    Concurrent Repairs: Overlapping blasting and coating with other fabrication work can lead to delays, as these tasks cannot always be performed simultaneously.
    Equipment and Weather Delays: Downtime caused by equipment breakdowns or adverse weather conditions adds to scheduling pressures.

• • Unpredictable Scope of Work

    Unknown Damage: The condition of coatings and surfaces is often unclear until vessels are docked or ballast tanks are inspected, requiring flexibility in planning and resources.
    Corrosion Risks: Severely corroded areas may necessitate unexpected welding and fabrication, further increasing timelines and costs.

• • Confined Spaces and Accessibility

    Challenging Work Areas: Ballast tanks, ship holds, and other confined spaces require specialized equipment, lighting, and ventilation to ensure safe and efficient operations.
    Logistical Constraints: Equipment often needs to be craned on and off ships, demanding precise coordination. In slipways, the angled positioning of vessels adds further complexity.

• • Environmental Challenges

    Dust Control: Abrasive blasting produces significant dust, which must be contained to prevent impacting other trades and nearby residential areas. Additional containment measures increase project costs.
    Noise Management: Noise generated by blasting operations must be minimized to avoid disturbing on-board crew, shipyard workers, and surrounding communities.
    Waterway Contamination: Strict regulations require heightened levels of containment to prevent abrasive or coating waste from polluting waterways. Heavy fines may be incurred for non-compliance.
    Waste Disposal: Managing and disposing of waste materials in compliance with environmental standards adds logistical and financial complexity.

• • Safety Challenges

    Hazardous Confined Spaces: Working in confined spaces poses risks such as toxic gas buildup, poor ventilation, restricted access, and communication difficulties.
    Operator Fatigue: High-thrust blasting activity and long shifts can lead to operator fatigue, increasing the risk of errors and injuries.
    Workplace Incidents: Crowded conditions with multiple trades working simultaneously elevate the likelihood of workplace accidents.
    Fall and Equipment Hazards: Working at heights and handling heavy equipment introduces significant safety risks, requiring robust safety protocols and training.

• • Crowded Workspaces

    Multiple Trades at Once: Welders, painters, blasters, inspectors, and crew members working simultaneously create congestion, slowing productivity and complicating operations.
    Stand-Down Crew: The presence of additional personnel on board further challenges safe and efficient project execution.

• • Quality Assurance Challenges

    Stringent Standards: Meeting high-quality requirements necessitates frequent inspections, which can delay progress.
    Inconsistent Results: Issues such as uneven blasting pressures, poor visibility, and abrasive embedment compromise coating adhesion and surface cleanliness, leading to rework and higher costs.

• Cost Overruns

  Labor Inefficiencies: Excessive man-hours required for blasting increase labor costs.
  Material Wastage: Inefficient abrasive usage and containment measures drive up material expenses.
  Budget Variations: Unforeseen damage, delays, and scope changes often result in budget overruns, impacting profitability.