NGC Code: The Intelligent Backbone of Maritime Asset Management

 

A White Paper by Narenta Gestio Consilium

Introduction: From Fragmentation to Fleet Intelligence

In today’s maritime industry, asset management is no longer just about maintenance logs and part lists—it is about interconnected systems, data-driven decisions, and regulatory foresight. The long-standing legacy coding structure, though historically significant, lacks the agility and digital readiness needed in modern shipbuilding, fleet operations, and ESG compliance.

Enter the NGC Code—a comprehensive maritime classification and asset intelligence framework developed by Narenta Gestio Consilium (NGC). Purpose-built to unify technical, operational, digital, and compliance domains, it represents a leap forward in how maritime assets are managed—from engine spares to AI-linked predictive tasks, from drydocking plans to environmental controls.

1. Why the NGC Code?

The NGC Code is not a rebadged legacy system. It is engineered from the ground up to solve critical maritime challenges:

1.1 Unified Maintenance Intelligence

• Supports Preventive (PM), Condition-Based (CD), Predictive (PdM), and Prescriptive (RxM) strategies.
• Aligns job frequencies with onboard conditions, risk profiles, and CBM analytics.

1.2 Automated Regulatory Traceability

• Each job, component, and spare is tagged with compliance relevance: ISM, Class, SOLAS, MARPOL, IMO, and EU ETS.
• Facilitates paperless surveys, inspections, and flag reviews.

1.3 Intelligent Spare Part Classification

• Precise categorisation: Critical (CS), Essential (ES), Consumable (CO/OC), with hazard linkage (IMDG Class 1–9).
• Enables stock-level alerts, job-triggered ordering, and cost-based planning.

1.4 Digital Twin & AI Integration

• Each equipment tag can link to real-time diagnostics, XA-tagged AI modules, and prescriptive analytics.
• Supports logical asset management aligned lifecycle modelling.

1.5 Cross-Vessel & MRP Integration

• Applies across entire fleets for comparability, budgeting, and MRP supplier linkage.
• Interfaces with financial and ERP systems via standard GL/NGC mappings.

2. Inside the NGC Code Structure

PART-ID Format

SUP-NGC-AA-NNN-Axx-Ayy-CCC
e.g., SUP-NGC-MM-FA-001-A20-A11-CS0

• AA = Function (e.g., FA = Diesel Engine)
• NNN = Equipment (e.g., 001 = Main Engine)
• A20 = Component Group (e.g., Cylinder Liner)
• A11 = Part Detail (e.g., Gasket)
• CS0 = Spare class + hazard (e.g., Critical + Non-Haz)

JOB-ID Format

JOB-NGC-AA-NNN-Axx-III
e.g., JOB-NGC-MM-FA-001-A20-10Y

• Defines job, interval, strategy, and links to AI and parts.

Boolean Flags for Decision Filters

• CRIT_EQP, ENV_CRIT, ISM, CLASS_SURVEY, REGULATORY_TASK, LINKED_AI

3. PMS Grouping & Overhaul Triggers

• Each equipment (e.g., EQ-NGC-MM-FA-001) is linked to a PMS_GROUP_ID (e.g., PMS-NGC-MM-FA-001).
• All associated jobs fall under this umbrella, enabling structured display, filtering, and automation.
• Spare part reorder logic is tied to job intervals and supplier lead times—e.g., for a 10-year cylinder overhaul, reorder flags are triggered at a 12-month offset if the lead time is 10 months.

4. Supplier & Inventory Integration

NGC is directly mapped to a classified Master Supplier List, segmented as:

• MKR-xxx – OEM/Makers
• CNS-xxx – Consumables & general
• SRV-xxx – Service providers

Each is assigned:

• NGC Code(s) served
• Standards: ISO 9001, 14001, 45001, OSHA, BizSAFE
• Class/Flag approvals, audit readiness, and scope (local/global)

This data connects to MRP inventory and MPMS tasks to ensure automated sourcing.

5. Alignment with Asset Management

The NGC Code is built on logical asset management principles, including:

Asset Management Requirement	NGC Implementation
Asset Definition	Every asset, job, and part is assigned a unique, structured identifier (e.g., NGC-MM-FA-001).
Lifecycle Strategy	Jobs aligned with time/condition intervals, spares tagged by CRIT level.
Risk-Based Planning	Uses CRIT_EQP, ENV_CRIT + MTBF/RCM integration.
Policy Integration	AM policy references the NGC structure as the classification backbone.
Continuous Improvement	Feedback from overdue jobs, spare usage, and audits revises PMS.

6. Use Case Snapshot: Main Engine PMS

Component	Code	Spare	Strategy	Job ID
Cylinder Liner	A20	CS0	PM + RxM	JOB-NGC-MM-FA-001-A20-10Y
Piston Crown	A30	CS0	PM + RxM	JOB-NGC-MM-FA-001-A30-05Y
Fuel Pump	A40	ES0	PM	JOB-NGC-MM-FA-001-A40-03Y
Gasket Kit	A50	CO0	PM	JOB-NGC-MM-FA-001-A50-03Y

Conclusion: NGC = Structured Intelligence for the Maritime Asset Future

The NGC Code is more than a framework—it’s a decision-enabling, compliance-aligned, and future-proof operating model for fleet managers, shipyards, and owners.

It replaces fragmented tracking and reactive planning with:

• Real-time decision logic
• Logic-aligned asset control
• Spare-part lifecycle accuracy
• Supplier performance traceability
• Prescriptive maintenance integration

For shipbuilders, operators, and regulators seeking a single source of operational truth, the NGC Code is your foundation.

Next Steps:

Ready to audit-proof your PMS, digitise your vessel lifecycle, or streamline MRP? → [Contact Narenta Gestio Consilium for a pilot implementation or digital demo.- Use Blog Contact Form.]

Prescriptive Maintenance

Prescriptive maintenance in marine engineering is an advanced maintenance strategy that combines predictive analytics with actionable, tailored recommendations. It uses big data, artificial intelligence (AI), and machine learning to analyse real-time data and provide specific, evidence-based solutions to maintenance challenges.

Unlike traditional or predictive maintenance approaches, prescriptive maintenance anticipates potential issues and prescribes precise mitigation actions based on the equipment’s condition, operational load, environmental factors, and future usage predictions.

By integrating AI, the system continuously learns and improves, identifying patterns and potential failures that human operators or basic predictive models might miss. This strategy ensures marine vessels operate optimally, enhancing efficiency, safety, and cost-effectiveness.

Real-Time Data Monitoring and Analysis

Real-time data collection from advanced sensors and IoT devices enables prescriptive maintenance. Data such as temperature, vibration patterns, and engine performance is continuously analysed to detect anomalies, trends, and potential issues before they escalate.

Decision Support Systems (DSS)

DSS leverages advanced analytics and expert systems to provide actionable recommendations. It evaluates cost implications, time requirements, and resource availability to ensure maintenance actions are effective, timely, and aligned with operational priorities.

 Failure Mode and Effects Analysis (FMEA)

FMEA systematically identifies potential failure points, their causes, and their impacts on marine systems. It prioritises critical maintenance tasks, helping engineers mitigate risks and enhance vessel reliability and safety.

Maintenance Scheduling Optimisation

Using predictive algorithms, this component identifies optimal maintenance schedules, preventing early or delayed interventions. It considers factors like equipment conditions, failure rates, operational schedules, and external conditions to maximise uptime and reduce disruptions.

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Benefits of Prescriptive Maintenance

Informed Decision-Making

Prescriptive maintenance equips marine engineers with actionable insights based on real-time data, enabling proactive and informed decision-making to preempt failures and optimise operations.

Optimised Maintenance Operations

This approach eliminates unnecessary interventions and reduces downtime by timing maintenance precisely. It ensures the smooth integration of maintenance activities with operational schedules.

Enhanced System Reliability

By addressing issues before they escalate, prescriptive maintenance ensures the consistent performance of marine systems, reducing risks of unexpected breakdowns and enhancing operational safety.

Cost Savings

Proactive maintenance reduces emergency repair costs and extends equipment life. This cost-effective strategy lowers overall operational expenses and boosts profitability.

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 Examples

Prescriptive Maintenance for Dual-Fuel MAN B&W Engines

Prescriptive maintenance optimises fuel usage and prevents failures for Aframax tankers equipped with dual-fuel MAN B&W engines. Real-time sensor data, such as exhaust temperature and fuel pressure, predicts inefficiencies or wear. Tailored actions like fuel injection adjustments or targeted inspections reduce fuel consumption and emissions while avoiding operational disruptions.

Prescriptive Maintenance for Tanker Hulls

Hull stress monitoring systems and corrosion sensors predict areas prone to damage. For instance, increased corrosion activity might prompt proactive inspections or recommend route adjustments. This ensures structural safety, compliance with maritime standards, and significant cost savings on repairs.

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Conclusion

Prescriptive maintenance represents a paradigm shift in marine engineering, leveraging IoT, AI, and machine learning to transform data into actionable insights. This proactive approach enhances reliability, reduces operational costs, and ensures compliance with safety standards. By adopting prescriptive maintenance, the maritime industry can achieve safer, more efficient operations, ensuring the longevity of vessels and equipment in demanding marine environments.

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FAQs on Prescriptive Maintenance in Marine Engineering

1. What is prescriptive maintenance, and how is it different from predictive maintenance?
Prescriptive maintenance predicts potential issues and provides actionable recommendations tailored to specific circumstances, making it more advanced than predictive maintenance.

2. How does prescriptive maintenance improve vessel safety?
Prescriptive maintenance enhances vessel safety and reduces the risk of equipment failure at sea by identifying potential issues early and prescribing precise maintenance actions.

3. What technologies enable prescriptive maintenance?
Prescriptive maintenance relies on AI, machine learning, IoT sensors, big data analytics, and real-time monitoring systems to gather and analyse operational data.

4. Can prescriptive maintenance help reduce costs?
Yes, it lowers costs by preventing major breakdowns, optimising maintenance schedules, and extending equipment life through timely interventions.

5. What are practical examples of prescriptive maintenance applications in the marine industry?
Examples include optimising dual-fuel engine performance and predicting hull corrosion for targeted maintenance, improving efficiency and reducing costs.

Disclaimer:

Out of Box Maritime Thinker © by Narenta Gestio Consilium Group 2022 and Aleksandar Pudar assumes no responsibility or liability for any errors or omissions in the content of this paper. The information in this paper is provided on an "as is" basis with no guarantees of completeness, accuracy, usefulness, or timeliness or of the results obtained from using this information. The ideas and strategies should never be used without assessing your company's situation or system or consulting a consultancy professional. The content of this paper is intended to be used and must be used for informational purposes only.

2.13. PRESCRIPTIVE MAINTENANCE

2.13.1 INTRODUCTION

2.13.1.1 DEFINITION

Prescriptive maintenance in marine engineering is an evolution of maintenance strategies, melding the foresight of predictive maintenance with the acuity of actionable recommendations. It is a holistic approach that forecasts potential maintenance issues and proactively suggests the best mitigation action. This strategy harnesses the power of advanced analytics, big data, artificial intelligence (AI), and machine learning algorithms to create a dynamic maintenance environment.

At its core, prescriptive maintenance in marine engineering leverages a wealth of data from various sources – including sensors on marine equipment, historical maintenance records, and operational parameters. This data is continuously collected and analysed in real-time. Unlike traditional maintenance approaches that rely on set schedules or reactive measures following a failure, prescriptive maintenance anticipates problems before they occur and recommends precise, evidence-based actions.

These recommendations are not generic; they are tailored to the specific circumstances of each vessel and its machinery. The system considers various factors, such as the current condition of equipment, the operational load, environmental conditions, and even the predicted future usage of the vessel. Doing so can suggest the most effective maintenance actions, whether immediate repairs, scheduled downtime, or adjustments in operation to prolong equipment life.

Integrating AI and machine learning allows the system to learn from each intervention, improving its accuracy and effectiveness. This learning capability means the system becomes more adept at identifying subtle patterns or signs of impending issues that human operators or simpler predictive models might miss.

Prescriptive maintenance in marine engineering is about moving beyond simply predicting problems to providing actionable, intelligent solutions that optimise the performance and longevity of marine vessels and their equipment. It represents a paradigm shift from reactive or even predictive maintenance to a more sophisticated, data-driven approach that empowers marine engineers to make informed, strategic decisions that enhance efficiency, safety, and cost-effectiveness in marine operations.

2.13.2 KEY COMPONENTS OF PRESCRIPTIVE MAINTENANCE

2.13.2.1 REAL-TIME DATA MONITORING AND ANALYSIS

In prescriptive maintenance, real-time data monitoring and analysis stand as the foundation. Advanced sensors and Internet of Things (IoT) devices are deployed extensively across marine vessels, continuously gathering data from various components like engines, navigational systems, and hull structures. This data, ranging from temperature readings to vibration analysis, is then transmitted in real-time for analysis.

The analysis involves sophisticated algorithms and data analytics tools that scrutinise this data stream for anomalies, trends, and patterns. This process detects issues and predicts future problems based on subtle changes in data readings. For instance, a slight increase in engine temperature or a minor change in vibration patterns could indicate a potential future failure. By identifying these issues early, prescriptive maintenance allows for interventions that prevent more significant problems and costly repairs.

 

2.13.2.2 DECISION SUPPORT SYSTEMS (DSS)

Decision Support Systems (DSS) are integral to prescriptive maintenance. These systems take the analysis provided by real-time monitoring and use it to offer actionable maintenance recommendations. DSS in marine engineering is multifaceted; it incorporates data analytics, expert systems, and sometimes even AI to process the data and provide well-rounded advice.

The strength of a DSS lies in its ability to consider a wide array of factors before making a recommendation. These factors include the cost implications of different maintenance actions, the required time, the availability of resources (like spare parts or technical personnel), and the potential impact on vessel operations. By balancing these variables, a DSS ensures its maintenance actions are timely, cost-effective, and resource-efficient.

2.13.2.3 FAILURE MODE AND EFFECTS ANALYSIS (FMEA)

Failure Mode and Effects Analysis (FMEA) is a systematic, structured approach for analysing potential reliability problems at the earliest stages. In marine engineering, FMEA involves a detailed examination of aquatic systems and components to identify all possible failure modes, their causes, and their effects on the overall system's performance.

FMEA in prescriptive maintenance is proactive. It aims to identify potential failure points before they occur, understanding how and why these failures might happen and the consequences thereof. This analysis helps prioritise maintenance tasks by highlighting the most critical areas that need attention. It also aids in developing strategies to mitigate risks, thereby enhancing the safety and reliability of marine systems.

2.13.2.4 MAINTENANCE SCHEDULING OPTIMISATION

The final key component is the optimisation of maintenance scheduling. This aspect uses algorithms and predictive models to determine the most opportune times for conducting maintenance activities. These algorithms consider various factors, such as the condition of equipment, predicted failure rates, operational schedules of the vessel, and even external factors like weather conditions and port availability.

Maintenance scheduling optimisation ensures that maintenance activities are conducted on time (which can be wasteful) or too late (which can lead to failure and operational disruptions). By finding the optimal balance, this component of prescriptive maintenance maximises equipment uptime, enhances operational efficiency, and reduces costs associated with unscheduled downtimes and emergency repairs. It is a strategic approach that aligns maintenance activities with the vessel's operational requirements and constraints, ensuring smooth, uninterrupted marine operations.

2.13.3 BENEFITS OF PRESCRIPTIVE MAINTENANCE

2.13.3.1 INFORMED DECISION-MAKING

One of the most significant benefits of prescriptive maintenance is its role in fostering informed decision-making. This approach provides a detailed, data-driven view of the health and performance of marine equipment and systems. By leveraging the insights gained from continuous monitoring and advanced analytics, marine engineers and decision-makers are equipped with a comprehensive understanding of their vessel's operational status. This knowledge allows them to preempt failures before they occur and make decisions that optimise performance. For instance, if data indicates an emerging problem in the engine room, decisions can be made to address the issue during a scheduled docking rather than facing an unexpected failure at sea.

2.13.3.2 OPTIMISED MAINTENANCE OPERATIONS

Prescriptive maintenance also leads to more optimised maintenance operations. Traditional reactive maintenance often results in unplanned downtime and rushed, costly repairs. In contrast, prescriptive maintenance uses predictive analytics to time maintenance activities precisely, ensuring that interventions are carried out when they are most effective and least disruptive. This approach minimises downtime and ensures that maintenance tasks are performed on time. The result is a smoother, more efficient operational workflow, seamlessly integrating maintenance activities into the vessel's schedule.

2.13.3.3 ENHANCED SYSTEM RELIABILITY

Enhancing system reliability is a core advantage of prescriptive maintenance. This strategy proactively addresses potential issues, preventing equipment failures before they occur. Doing so significantly reduces the risk of unexpected breakdowns and ensures all systems function optimally. Enhanced reliability is not just about preventing failures; it's also about ensuring that the vessel operates at peak efficiency, which is crucial for safety and operational success in the demanding marine environment.

2.13.3.4 COST SAVINGS

Finally, prescriptive maintenance can lead to substantial cost savings. The proactive nature of this maintenance strategy means that issues are often resolved before they escalate into major problems, thus avoiding expensive emergency repairs. Additionally, the overall operational costs are lowered by reducing downtime and extending the life of equipment through timely and precise maintenance interventions. This cost-effectiveness is a significant benefit, especially regarding the high operational costs associated with marine vessels. The savings achieved through prescriptive maintenance can be redirected towards other critical areas of marine operations, further enhancing the efficiency and profitability of maritime enterprises.

2.13.4 EXAMPLES

2.13.4.1 PRESCRIPTIVE MAINTENANCE FOR DUAL FUEL MAN B&W MAINE ENGINE

Take the case of an Aframax tanker equipped with a dual-fuel MAN B&W main engine. This type of engine, capable of running on traditional marine fuels and liquefied natural gas (LNG), presents unique maintenance challenges due to its complex fuel systems and combustion processes.

The vessel's management can more effectively optimise fuel usage and anticipate maintenance needs by implementing prescriptive maintenance. For example, sensors embedded in the engine can monitor parameters such as fuel pressure, exhaust gas composition, and cylinder temperatures in real-time. When analysed, this data can indicate wear or inefficiencies in fuel combustion.

It can suggest a specific action if the system detects an anomaly, like a higher-than-normal exhaust gas temperature. This might include adjusting the fuel injection timing or planning a detailed inspection of certain engine components during the next port call. Such actions prevent unexpected engine failures and ensure the engine operates efficiently, reducing fuel consumption and emissions - crucial for compliance with international maritime regulations.

In a real-world scenario, this could mean the difference between a smooth, uninterrupted voyage and an unscheduled stop due to engine failure, significantly impacting the tanker's operational costs and reliability.

2.13.4.2 PRESCRIPTIVE MAINTENANCE FOR HULL (TANKER)

Consider an Aframax tanker navigating global trade routes, where its hull is subjected to various stress factors like varying sea conditions, temperature fluctuations, and corrosive environments. Prescriptive maintenance can be particularly beneficial in maintaining the hull's integrity.

Through the integration of hull stress monitoring systems and corrosion detection sensors, prescriptive maintenance can predict areas on the tanker's hull that are prone to corrosion or structural stress. For example, sensors might detect increased corrosion activity levels in certain hull sections, potentially caused by a coating failure or an electrochemical reaction.

Upon analysing this data, the system might suggest a targeted inspection and maintenance plan for the affected area during the next dry docking. It could also recommend adjustments to voyage routes or speeds to reduce stress on vulnerable hull sections. Additionally, the analysis might indicate the need for a different type of protective coating or anodic protection system in the future.

In a practical scenario, this level of detailed, proactive maintenance can prevent structural failures, which are critical in maintaining the safety and integrity of the vessel. It also ensures compliance with maritime safety standards and can significantly reduce the costs associated with significant hull repairs. For an Aframax tanker, this approach not only guarantees structural safety but also enhances the operational efficiency and longevity of the vessel.

2.13.5 CONCLUSION

Prescriptive maintenance marks a revolutionary stride in marine engineering maintenance. This approach, underpinned by integrating advanced analytics and real-time data acquisition, transcends traditional maintenance methodologies. It embodies a proactive, predictive, and precise strategy that substantially augments operational efficiency, elevates safety standards, and bolsters cost-effectiveness in the demanding sphere of marine engineering.

In the dynamic and often unpredictable environment of marine operations, where vessels are subject to diverse and harsh conditions, the importance of a maintenance strategy that can predict and prescribe cannot be overstated. Prescriptive maintenance leverages cutting-edge technologies like IoT, AI, and machine learning, transforming vast data sets into actionable insights. These insights empower marine engineers and decision-makers with the foresight to preemptively address potential issues before they escalate into costly and hazardous situations.

The implementation of prescriptive maintenance strategies, as illustrated in the examples of dual-fuel MAN B&W main engines and Aframax tanker hulls, demonstrates its effectiveness in enhancing the reliability and longevity of critical marine systems. By optimising maintenance operations, reducing unplanned downtimes, and extending equipment life, prescriptive maintenance contributes to a significant reduction in operational costs. More importantly, it plays a crucial role in ensuring the safety of the vessel, its crew, and the marine environment.

In summary, prescriptive maintenance is a cornerstone in advancing marine engineering maintenance. It is not merely an improvement over existing maintenance practices but a transformative approach that aligns with the evolving needs of modern marine operations. By adopting prescriptive maintenance, the maritime industry is better equipped to navigate the complexities of today's marine environment, ensuring smoother, safer, and more efficient voyages across the world's oceans.

 

Disclaimer:

Out of Box Maritime Thinker © by Narenta Gestio Consilium Group 2022 and Aleksandar Pudar assumes no responsibility or liability for any errors or omissions in the content of this paper. The information in this paper is provided on an "as is" basis with no guarantees of completeness, accuracy, usefulness, or timeliness or of the results obtained from using this information. The ideas and strategies should never be used without assessing your company's situation or system or consulting a consultancy professional. The content of this paper is intended to be used and must be used for informational purposes only.

Computer-Based Maintenance Management Systems (CMMS)

 A Computerised Maintenance Management System (CMMS) or Marine ERP with PMS software is an integrated solution for efficiently managing maintenance and inventory operations. These systems also aid in human and capital resource management, but it is essential to understand that CMMS is a tool—not a replacement for strategic management. This chapter examines the marine industry's CMMS functionalities, benefits, limitations, and challenges.

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Key CMMS Functionalities

A CMMS integrates various functions to streamline maintenance activities, including:

• Equipment and asset management
• Work order and history tracking
• Inventory control
• Preventive maintenance planning and scheduling
• Human resource and purchasing management
• Invoice matching and accounts payable

These functionalities ensure seamless data management, task execution, and report generation. However, CMMS effectiveness relies heavily on accurate and consistent data input.

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Essential CMMS Data Files

Equipment/Asset Identification and Specifications

Each equipment record in a CMMS contains essential details like equipment type, location, and specifications. This data ensures efficient work order creation, verification, and planning. Comprehensive equipment records eliminate manual searches and streamline maintenance workflows.

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Equipment/Asset Hierarchies

Hierarchies group equipment into broader categories, enabling:

• Aggregated maintenance cost tracking
• Simplified equipment location identification
• Comprehensive historical data analysis for root cause failure identification

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Bills of Materials

Bills of materials (BOMs) link to specific equipment, listing major components and parts. Accurate BOMs aid in planning work orders and inventory management, ensuring the right parts are always available.

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Spare Parts and Inventory Management

An effective CMMS maintains real-time inventory records, tracks usage trends, and automates reorder processes. Integration with procurement ensures parts availability, reducing downtime and costs.

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CMMS User Roles and Applications

Maintenance Teams

Maintenance personnel use CMMS for work order initiation, planning, scheduling, and performance tracking. Features like automatic preventive maintenance (PM), work order generation, and resource allocation enhance efficiency.

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Engineering Teams

Engineers leverage CMMS for project planning, equipment performance tracking, and modification history management. These insights help optimise maintenance strategies and improve equipment reliability.

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Vessel Operations

Onboard crews use CMMS for:

• Downtime Scheduling: Planning routine maintenance during scheduled equipment downtime.
• Repair Request Backlog: Monitoring work order statuses without reliance on external communication.
• Failure Analysis: Analysing repair histories by cause and effect to identify systemic issues.

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Inventory Control

Inventory personnel manage parts usage, cross-reference inventory with equipment, and plan stock replenishment. Automated requisitioning and part-to-equipment cross-referencing improve inventory accuracy and reduce costs.

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Purchasing Teams

Integrated CMMS systems streamline purchasing by consolidating requisitions, automating reorders, and managing supplier relationships. This integration reduces administrative overhead and ensures timely part availability.

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Accounting and Finance

CMMS aids in cost tracking, budget preparation, and compliance with standards like ISO 9000. Accurate cost allocations and comprehensive maintenance histories ensure efficient financial management.

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Executive Management

Senior managers use CMMS for:

• Budget Tracking: Monitoring costs versus budgets for better resource allocation.
• Regulatory Compliance: Ensuring adherence to IMO, STCW, ILO-MLC, and ISO standards.

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Benefits of a CMMS

• Efficient Data Management: Automated sorting, summarising, and displaying of maintenance data.
• Enhanced Preventive Maintenance (PM): Reliable scheduling and notification systems ensure timely task execution.
• Streamlined Inventory Management: Automated replenishment and reduced stockouts.
• Accurate Scheduling: Resource-based work order scheduling improves task completion rates.

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Limitations of a CMMS

Despite its benefits, CMMS is not a replacement for skilled personnel. Key limitations include:

• Dependency on Proper Implementation: Partial implementations often lead to underutilisation.
• Resource Constraints: Successful deployment requires time, training, and commitment.
• Lack of Cultural Adaptation: Resistance to change can hinder system adoption.

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Common Reasons for CMMS Failure

1. Partial Implementation: Due to incomplete setups, many organisations use only 9% of CMMS functionality.
2. Inadequate Resources: Underfunding and understaffing derail implementations.
3. Misaligned Expectations: Overreliance on CMMS without addressing systemic issues.
4. Poor Communication: Lack of a clear project plan leads to confusion and inefficiency.
5. Work Culture Resistance: With staff buy-in, CMMS adoption is expanded.

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Steps to Ensure CMMS Success

1. Comprehensive Planning: Define clear objectives and allocate sufficient resources.
2. Employee Training: Equip teams with the skills to utilise CMMS effectively.
3. Collaborative Approach: Involve cross-functional teams to align system functionalities with organisational goals.
4. Continuous Monitoring: Regularly review and optimise CMMS usage to maximise ROI.

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FAQs on CMMS in the Marine Industry

1. What is the primary purpose of a CMMS in marine operations?
A CMMS improves maintenance efficiency by centralising data, automating workflows, and optimising vessel resource allocation.

2. How does a CMMS streamline inventory management?
A CMMS tracks inventory in real-time, automates reorders and provides usage insights, ensuring parts availability while reducing overstock and costs.

3. What are the key challenges of implementing a CMMS?
Challenges include partial implementations, inadequate training, resistance to cultural changes, and lack of stakeholder commitment.

4. Can a CMMS ensure regulatory compliance?
A CMMS assists with compliance by maintaining records and schedules for IMO, STCW, ILO-MLC, and ISO standards.

5. How can organisations maximise ROI from a CMMS?
To maximise ROI, ensure full implementation, provide thorough training, involve all stakeholders, and regularly review system performance.

Disclaimer:

Out of Box Maritime Thinker © by Narenta Gestio Consilium Group 2022 and Aleksandar Pudar assumes no responsibility or liability for any errors or omissions in the content of this paper. The information in this paper is provided on an "as is" basis with no guarantees of completeness, accuracy, usefulness, or timeliness or of the results obtained from using this information. The ideas and strategies should never be used without first assessing your company's situation or system or consulting a consultancy professional. The content of this paper is intended to be used and must be used for informational purposes only.

Computerised Planning and Scheduling: Streamlining Marine Maintenance Management

 The adoption of marine ERP systems has revolutionized maintenance management in the marine industry, offering opportunities and challenges. Effective computerisation requires a thorough understanding of the core components of maintenance management, which apply to diverse maintenance tasks, including routine, preventive, corrective, shutdown, and emergency maintenance. Below, we delve into the essential aspects of computerised planning and scheduling for marine operations.

Key Components of Maintenance Management

1. Work Requests:
A work request communicates specific maintenance needs, detailing critical information such as the equipment number, job number, required work, approvals, and priority levels. Proper documentation ensures clarity for the maintenance team.

2. Work Orders:
Work orders outline the scope and specifics of maintenance tasks. They include equipment details, job numbers, work descriptions, and resources needed, such as materials, tools, and personnel. These documents form the foundation for planning, scheduling, and creating maintenance histories, streamlining future analyses.

3. Prioritisation:
Efficient prioritisation determines the urgency and criticality of maintenance tasks. By assessing operational impact, safety concerns, regulatory compliance, and resource availability, maintenance teams can address high-priority jobs effectively, optimising resource utilisation.

4. Work Planning:
Planning involves addressing the "5 Ws and 1 H":

• Why is the work needed?
• What needs to be done?
• Who will perform the task?
• Where will it take place?
• When will it occur?
• How will it be accomplished?

This structured approach identifies resources, risks, and steps, minimising downtime and reducing costs.

5. Scheduling:
Scheduling aligns resources with tasks to ensure maintenance occurs efficiently. Plans are typically organised daily, weekly, monthly, or annually, focusing on minimising disruptions while meeting deadlines.

Enhancing Marine Maintenance with Computerised Systems

Organised Databases:
Computerised systems maintain a centralised database, incorporating cost assignments, equipment identification, crew lists, and spare parts catalogues. These databases enable informed decision-making and efficient resource allocation.

Cost Assignments:
Clear cost allocation procedures help cost centres or departments track expenses, aligning with established accounting practices.

Equipment Identification:
Unique identification codes simplify tracking and maintaining equipment. Grouping similar equipment under categories enhances efficiency while preserving detail.

Crew Management:
Crew lists detailing trades, roles, and availability support efficient task assignments and resource tracking.

Benefits of Computerisation

1. Improved Maintenance Planning:
   Computerised systems offer tools for backlog management, resource allocation, and cost tracking, improving operational efficiency by up to 50%.

2. Enhanced Reporting and Analysis:
   Comprehensive reports provide insights into work orders, inventory usage, and equipment performance, supporting continuous improvement.

3. Streamlined Workflows:
   Integration of work orders, prioritisation, and scheduling ensures seamless communication and execution.

Implementation Steps for a Computerised Maintenance Management Program

1. Defining the Program:
Identify needs, costs, and system requirements. Then, decide whether to develop the software in-house or purchase an off-the-shelf package.

2. Organising the Implementation Team:
Form an interdisciplinary team with maintenance, data processing, and accounting expertise to oversee system definition and deployment.

3. Orientation and Training:
Educate personnel on using the system, from creating work requests to retrieving reports. Effective training ensures system adoption and utilisation.

4. Role Allocation:
Assign data entry, file maintenance, and report generation responsibilities to ensure smooth operations.

Features of an Effective Computerised Maintenance Management System (CMMS)

1. Online Inquiry:
Real-time access to work orders, materials, and equipment data reduces paperwork and enhances productivity.

2. Custom Report Generation:
Generate tailored reports for data-driven decisions, including equipment history, downtime, inventory valuation, and failure analysis.

3. Performance Monitoring:
Track performance against benchmarks using concise, actionable reports, including schedule compliance and backlog summaries.

The Importance of a Formal Work Order System

A work order system standardises maintenance operations, ensuring tasks are properly planned, prioritised, and tracked. This system:

• Facilitates resource allocation.
• Tracks performance metrics.
• Enhances communication between departments.

Implementing a Priority System: The RIME Approach

The Ranking Index for Maintenance Expenditures (RIME) system assigns priority levels based on equipment criticality and task importance. This structured approach minimises biases and aligns maintenance activities with operational priorities.

Advanced Features of Computerised Systems

Inventory Management:
A CMMS ensures spare parts availability by tracking inventory status, vendor information, and reorder requirements.

Equipment Monitoring:
Maintain detailed equipment histories, monitor performance trends, and optimise preventive maintenance schedules.

Performance Analysis:
Use advanced analytics to identify inefficiencies, evaluate costs, and improve maintenance strategies.

The Path Forward: Continuous Improvement

Planning and scheduling are dynamic processes. Regular audits of work orders, coupled with feedback from completed tasks, refine maintenance strategies, reducing delays and optimising outcomes.

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FAQs on Computerised Planning and Scheduling in Marine Maintenance

1. What is the primary benefit of computerising maintenance management in the marine industry?
Computerisation enhances efficiency by centralising data, streamlining planning, scheduling, and reporting processes, and reducing downtime and costs.

2. How does prioritisation improve maintenance operations?
Prioritisation ensures critical tasks are completed first, optimising resource allocation and preventing costly operational disruptions.

3. What features should a good CMMS include?
A robust CMMS should offer real-time data access, custom reporting capabilities, performance tracking, and seamless integration of inventory and work orders.

4. How can equipment identification systems benefit maintenance management?
Unique equipment identification simplifies tracking, supports preventive maintenance, and improves resource allocation.

5. Why is a formal work order system essential?
A work order system standardises processes, tracks performance, and ensures accountability, leading to better decision-making and resource management.

Disclaimer:

Out of Box Maritime Thinker © by Narenta Gestio Consilium Group 2022 and Aleksandar Pudar assumes no responsibility or liability for any errors or omissions in the content of this paper. The information in this paper is provided on an "as is" basis with no guarantees of completeness, accuracy, usefulness, or timeliness or of the results obtained from using this information. The ideas and strategies should never be used without first assessing your company's situation or system or consulting a consultancy professional. The content of this paper is intended to be used and must be used for informational purposes only.