In a bid to tackle the persistent issue of unscheduled downtime in container shipping, a recent study published in the Journal of Naval Architecture and Marine Engineering has shed light on the primary culprits behind these costly disruptions. Led by Araks Ekmekçioğlu from Yıldız Technical University’s Faculty of Naval Architecture and Maritime Department in Istanbul, the research delves into the operational drivers of unplanned downtime, offering a roadmap for fleet operators to enhance voyage reliability and cut costs.
The study, which analyzed 397 unplanned downtime events in a container ship fleet between 2017 and 2021, reveals that a staggering 89% of these incidents were related to propulsion or propulsion systems. Main engine events, in particular, were the most frequent, with 256 incidents and approximately 730 hours of downtime. “Despite their rarity, shaft, propeller, and stern-tube failures lead to very long delays per event, averaging around 96 hours,” Ekmekçioğlu notes, highlighting the significant impact of these less frequent but more severe failures.
The research employed a risk score, combining frequency, duration, and impact, to quantify the severity of downtime on operations. Using Pareto analysis, the team identified a small number of critical causes. The findings showed that oil mist detector (OMD) related events accounted for 63.1% of the total risk, with fuel injection and exhaust contributing 14.8% and 7.9%, respectively. Together, these three factors accounted for 85.8% of the risk, underscoring the areas where targeted interventions could yield the most significant improvements.
The study also utilized a Classification and Regression Tree (CART) model to extract variables driving downtime, supported by Ward’s linked hierarchical clustering. The results indicated that the longest downtimes were associated with fuel pump and injection failures, with a median duration of approximately 153.6 hours. Exhaust and lubrication-related failures were also found to be high-impact.
From a commercial perspective, the findings present a clear opportunity for fleet operators to prioritize condition-based maintenance packages and targeted spare parts management. By focusing on the critical clusters identified in the study, operators could aim for annual downtime reductions of 10-15%, leading to substantial cost savings and improved voyage reliability.
Ekmekçioğlu emphasizes the importance of rigorous OMD calibration and validation flows, as well as role-based training programs across the fuel, exhaust, and lubrication triad. “Key indicators should be defined to track improvements in diagnostic speed and overall downtime reduction,” she advises, pointing to a practical path forward for the industry.
For maritime professionals, the study underscores the need for a data-driven approach to maintenance and operations. By leveraging advanced analytical techniques like Pareto analysis and CART models, fleet operators can make informed decisions that enhance efficiency and reliability. The research serves as a valuable resource for those looking to optimize their operations and stay competitive in an increasingly challenging market.
In summary, the study by Ekmekçioğlu and her team offers a comprehensive analysis of unplanned downtime in container fleets, highlighting the critical areas that demand attention. By addressing these issues, maritime operators can achieve significant improvements in operational efficiency and cost savings, ultimately enhancing their competitive edge in the global shipping industry.