A new task-force-service department of the Uetersen Maschinenfabrik HATLAPA has been introduced to decrease re-equipment and installation time as well as increase flexibility in delivering marine equipment.
Uetersen – Since the ordering of new vessels is declining due to the economic downturn, service, repairs, alterations and spare parts delivery are of growing importance in the marine industry. The HATLAPA Uetersener Maschinenfabrik is aware of the potential that these aspects could have in driving a profit. The 450 employee-strong organisation with its headquarters in Uetersen (Kreis Pinneberg) near Hamburg, Germany, has created a department whose core responsibility it is to take on special assignments with a more flexible and quicker response time. "This means huge time savings for the ship owners, freighters and ship managers as the task force can assist them a lot quicker", Hartmut Opitz declares proudly.
The first point of contact at HATLAPA when a vessel needs assistance is the marine engineers. This improves response time, which was recently shown when a damaged ship could be repaired very quickly, and on another occasion HATLAPA enabled a cruise ship to continue its journey to the Caribbean on schedule. In one instance HATLAPA successfully exchanged a winch in a record time of six weeks, rather than the predicted six months, thus saving the ship owner valuable time. "Another time, HATLAPA showed its ability to respond to sudden changes to a customer’s needs and was able to bring the delivery date forward by a month", proclaims Opitz. "Whatever happens out at sea, HATLAPA will always be prepared and ready to meet customers’ needs", the Service Manager emphasises.
For instance, a German containership had a collision in the North Sea, colliding with a much larger vessel, and the steering gear had been damaged. The collision had been so severe that the 260metre-long "container monster" had a leak measuring the height of the port-side engine room. As water continued to run through the leak, the vessel was towed to shallower waters in order to prevent the ship from sinking. During the accident, a fire had also started onboard but could be extinguished by the crew: three of the 900 containers went overboard, the crew suffered from smoke inhalation and had to seek medical assistance –the journey to the destination in the Caribbean was definitely over.
That was the scene when HATLAPA received a call from a ship owner in Hamburg the following morning. Both of the combined anchor and mooring winches in the ship’s bow had been completely damaged in the accident and had to be replaced, and the vessel had to go through a complete overhaul. The ship owner had originally been told that the delivery time for the replacement winches was six months. However, the Hamburger ship owner did not want to wait that long and started making phone call to different companies selling deck machinery. Opitz received all of the data of the damaged machinery via email and discussed with the different departments within HATLAPA how they could provide a solution to the dilemma swiftly. The specialist winches that the damaged vessel had had on board were no longer in stock, but it was possible to gain the four much needed winches from another customer’s order and assemble them so that they made up the two specialist winches, that matched the specification of the winches from the damaged vessel. "Make two into four –a lucky streak and challenge at the same time", was what Opitz was able to tell the ship owner on the same day. A particular challenge, as the chain sprockets had to be manufactured in house, due to very long lead times. HATLAPA was then asked to put together a formal quotation for the delivery and fitting of the ordered machinery. Opitz spoke to all departments involved to start the quoting process and had an estimate ready the very next day: with a lead time of nine weeks for delivery and installation of the machinery. However, this was still too long –wasn’t there any way to make it happen faster, enquired the ship owner.
This is when the Task Force Service team stepped in. The group was created three years ago for cases just like this. Within this group, department managers from engineering, purchasing, service, sales and production are involved. The group of specialists investigated how to shorten the lead time. "We have come to the conclusion that in special cases like this, with considerable effort, the lead time could be reduced to seven weeks", recalls Opitz. This included shift work and overtime on weekends. The ship owner was delighted, and approved the order only 16 days after the collision.
Six weeks later, a week earlier than discussed, the specialist job was delivered from Uetersen to the repairs shipyard in Hamburg and two weeks later the unlucky vessel was already back in the water –not even three months after the collision. In only eight weeks the multipurpose vessel had been restored to its original condition.
Another similar story to this was a well-known cruise provider from the United States of America. The vessel was in need of new, more powerful steering gear for its 170 metre long and 30,000 register tons, not even 10-year old cruise ship that can accommodate up to 500 passengers. HATLAPA was to deliver two completely new steering systems, each of which was to deliver 500 Kilo-Newton metres of rudder torque at the blade, thus enabling a 45 degree turn for the vessel. The initial lead time to build and install the systems was six months, but suddenly; the ship owner changed the terms: the steering gear was to be ready a month earlier, so HATLAPA was told by the main contractor. Each delay would cause problems and could kill the project off completely, was the message HATLAPA was told very clearly. The cruise ship was not to miss the considerable profit generated from the Christmas and New Year-celebration cruises in the Caribbean under any circumstances. Service manager Opitz was alarmed and called the Task Force for a consultation. There was not much flexibility in the making of the steel castings and forgings that had been subcontracted out. Those works alone were to take 10-12 weeks. As a result, the time savings had to be made within HATLAPA’s internal processes and installation of the equipment – a highy challenging task for everyone involved. Opitz: "we shed blood, sweat and tears." The determination of the workers paid off in the end: the new, tighter schedule was kept and the steering gear was delivered on time. Opitz’s conclusion was "We were happy to be able to assist the ship owner so quickly and without much paperwork and at the same stayed in line with the technical specifications and our standards.
Every fifth task at HATLAPA nowadays is aimed at the service and spares business and the number is increasing steadily. "In this field of work, customers are relying on HATLAPA’s quick and flexible response", stresses Service manager Opitz. "Whether is it deck machinery or steering gear, we can take on any task regardless on the type of vessel." Whether it is a ferry, tanker, freight vessel or a cruise ship –HATLAPA can provide the perfect solution to the problem. Even a NATO navy supply ship is currently being fitted with a completely new steering gear system. "Globally, we are the only company that can produce all types and sizes of steering gear. And if necessary, we have the in-house expertise needed to fulfil any customer needs."