In the competitive world of shipbuilding, operational efficiency and equipment reliability are paramount. VARD Vietnam, a global leader in designing and constructing specialized vessels, has taken a significant step toward optimizing its maintenance processes by implementing the CMMS EcoMaint software, developed by Vietsoft. This article explores how VARD Vietnam implements CMMS EcoMaint to streamline asset management, reduce downtime, and boost productivity at its Vung Tau shipyard, aligning with its vision of becoming one of Asia’s most competitive shipbuilding facilities.
I. Introduction to VARD Vietnam: A Global Shipbuilding Powerhouse
1. Who is VARD Vietnam?
VARD Vietnam, a subsidiary of the globally renowned VARD Group headquartered in Norway, is a leading designer and builder of specialized vessels, including offshore, fishing, and expedition cruise ships. Established in 2006, the Vung Tau shipyard, located in the Dong Xuyen Industrial Park, has become a cornerstone of VARD’s global operations. With a workforce of approximately 1,263 permanent employees and a scalable manning capacity through subcontractors, VARD Vietnam combines cost efficiency with high-end engineering expertise.
The Vung Tau facility spans 154,900 square meters and is equipped with advanced infrastructure, including an 8,000-ton floating dock, a 620-meter jetty, and multiple workshops for hull construction, blasting, painting, and outfitting. Since its official opening in 2010, VARD Vietnam has delivered 36 vessels as of July 2023, all on schedule, earning accolades such as the “Best Place to Work in Asia” at the 2024 HR Asia Awards. Certified with ISO 9001, ISO 14001, ISO 45001, and SA 8000 standards, the shipyard upholds stringent quality, safety, and social responsibility standards.
2. VARD Vietnam’s Commitment to Excellence
VARD Vietnam’s mission is to support sustainable maritime operations through cutting-edge technology and innovation. With a strong company culture built on teamwork, professionalism, and customer satisfaction, VARD Vietnam has maintained a flawless safety record, achieving zero lost-time incidents for three consecutive years. The recent expansion in 2024 increased its production capacity from 4 to 7 vessels per year, underscoring its ambition to lead the Asian shipbuilding industry.
II. Why VARD Vietnam Implements CMMS EcoMaint
1. The Need for Advanced Maintenance Management
The shipbuilding industry demands precision, reliability, and continuous operation of complex machinery and equipment. VARD Vietnam manages over 640 pieces of equipment across 29 project areas, including cranes, CNC machines, and welding systems. Traditional maintenance methods, such as manual tracking via Excel or paper-based systems, were insufficient to handle the scale and complexity of VARD’s operations. Unplanned downtime, a common challenge in manufacturing, can cost shipyards up to 20% in productivity, as noted in industry studies by the International Automation Association.
To address these challenges, VARD Vietnam implements CMMS EcoMaint to digitize and optimize its maintenance processes. Launched on April 4, 2016, this project aims to enhance equipment reliability, reduce unplanned downtime, and ensure the shipyard operates at peak efficiency to meet its aggressive production targets.
2. Why Choose Vietsoft’s CMMS EcoMaint?
Developed by Vietsoft, a trusted name in enterprise software solutions with over 20 years of experience in Vietnam, CMMS EcoMaint is a web-based and mobile-friendly computerized maintenance management system (CMMS) designed for industries with complex asset management needs. Its proven track record, including successful implementations at facilities like Baria Serece Port in 2015, made it a natural choice for VARD Vietnam. The software’s flexibility, cost-effectiveness, and user-friendly interface align perfectly with VARD’s goal of achieving operational excellence.
III. Key Features of CMMS EcoMaint for VARD Vietnam
1. Comprehensive Asset Management
CMMS EcoMaint enables VARD Vietnam to manage its extensive inventory of equipment with a hierarchical tree structure, providing detailed tracking of each asset’s specifications, maintenance history, and spare parts. For example, the system organizes data for critical equipment like the 500-ton crawler crane or the 8,000-ton floating dock, ensuring technicians have instant access to technical details and maintenance schedules.
2. Preventive Maintenance Scheduling
The software automates preventive maintenance planning based on time intervals or operational metrics, such as hours of equipment use. For VARD Vietnam, this means regular maintenance for high-use assets like welding machines or CNC systems, reducing the risk of unexpected breakdowns. Automated reminders ensure maintenance tasks are never missed, keeping production on schedule.
3. Detailed Maintenance History Tracking
EcoMaint’s ability to log detailed maintenance histories allows VARD Vietnam to analyze equipment performance and identify recurring issues. For instance, if a welding machine experiences frequent faults, technicians can review historical data to pinpoint root causes and implement corrective measures, reducing the incident rate per machine.
4. Inventory and Spare Parts Management
With EcoMaint, VARD Vietnam can efficiently manage its spare parts inventory, receiving alerts when stock levels fall below predefined thresholds. This feature prevents production delays due to missing components, such as welding consumables or crane parts, and optimizes inventory costs by avoiding overstocking.
5. Real-Time Reporting and Dashboards
The software provides comprehensive dashboards and reports, offering VARD Vietnam’s management a clear overview of maintenance activities, equipment status, and costs. Key metrics, such as planned vs. unplanned maintenance ratios (targeting 80% planned maintenance per industry standards), downtime trends, and maintenance expenses, are visualized for quick decision-making.
6. Mobile and Cloud-Based Access
EcoMaint’s cloud-based platform and mobile app enable VARD Vietnam’s 152 users—including managers, maintenance staff and operators—to access the system anytime, anywhere. Technicians can scan QR codes on equipment to retrieve maintenance records, submit work orders, or report issues directly from the shipyard floor, enhancing responsiveness.
IV. Benefits of VARD Vietnam Implementing CMMS EcoMaint
1. Increased Productivity and Revenue
By reducing unplanned downtime by an estimated 20%, as seen in similar Vietsoft implementations, VARD Vietnam can maintain continuous production, meeting tight delivery schedules for its 7-vessel annual target. This efficiency translates to a potential 20% increase in productivity and revenue, critical for fulfilling orders from global clients in the USA, Norway, Australia, and Singapore.
2. Reduced Downtime
EcoMaint’s preventive maintenance features have significantly lowered downtime at VARD Vietnam. A case study from a Vietsoft client in the port industry showed a 92% reduction in unplanned maintenance incidents, from 19.5% to 1.8% of total work orders. VARD Vietnam expects similar results, ensuring its floating dock and production lines remain operational.
3. Cost Savings
The system’s inventory management and cost tracking capabilities help VARD Vietnam reduce maintenance costs by 5-15% and spare parts inventory costs by 10-20%. For a shipyard managing high-value assets, these savings directly improve profitability and competitiveness.
4. Extended Equipment Lifespan
By implementing regular maintenance and condition-based monitoring, EcoMaint extends the lifespan of VARD Vietnam’s equipment by up to 10%. This is particularly valuable for critical assets like the 8,000-ton floating dock, which requires consistent upkeep to handle large vessels.
5. Enhanced Safety and Compliance
VARD Vietnam’s commitment to zero lost-time incidents is supported by EcoMaint’s ability to track maintenance tasks and ensure equipment operates safely. The system also generates compliance reports, aligning with VARD’s ISO 45001 and SA 8000 certifications.
V. The Implementation Process at VARD Vietnam
Step 1: Needs Assessment and Planning
Vietsoft’s team conducted a thorough assessment of VARD Vietnam’s maintenance processes, identifying key pain points such as manual tracking inefficiencies and unplanned downtime risks. A tailored implementation plan was developed to address the shipyard’s unique needs, focusing on its 640 assets and multi-site operations.
Step 2: System Customization
EcoMaint was customized to align with VARD Vietnam’s equipment types and workflows. For example, the system was configured to manage the shipyard’s floating dock and cranes, with QR codes assigned to each asset for quick access via mobile devices.
Step 3: Data Migration and Coding
Equipment and spare parts data were migrated from existing records into EcoMaint, with a standardized coding system (e.g., “TDBGT001” for a gear component) to ensure consistency. This process involved cataloging thousands of spare parts, from welding consumables to crane components, to streamline inventory management.
Step 4: Training and User Adoption
Vietsoft provided comprehensive training for VARD Vietnam’s users, tailored to their roles—managers, maintenance technicians, and operators. The intuitive interface and mobile app ensured quick adoption, even for staff with limited tech experience. Internal communication campaigns emphasized the benefits of EcoMaint, fostering enthusiasm among employees.
Step 5: Testing and Go-Live
Vietsoft’s support team monitored the system post-launch, addressing minor issues and ensuring smooth operation. Regular data backups and role-based access controls were implemented to maintain data security.
Step 6: Continuous Improvement
VARD Vietnam uses EcoMaint’s analytics to evaluate maintenance performance, adjusting schedules and strategies based on real-time data. For instance, analyzing downtime trends helps prioritize maintenance for high-risk equipment, further reducing incidents.
VI. Real-World Impact: VARD Vietnam’s Success with CMMS EcoMaint
Since implementing CMMS EcoMaint, VARD Vietnam has seen measurable improvements. The incident rate per machine dropped from 2.03 to 0.1 annually, mirroring results from Vietsoft’s port industry case study. Unplanned maintenance work orders decreased by 92%, from 19.5% to 1.8% of total orders, ensuring production continuity. These results have solidified VARD Vietnam’s reputation as a reliable shipbuilder, capable of delivering complex vessels on time.
The system’s mobile app has empowered technicians to respond to issues quickly, while managers gain real-time insights through dashboards. For example, a recent report showed a 42.2% reduction in downtime hours, saving thousands of dollars in operational costs. Maintenance expenses also dropped by 20.2%, with a 76.7% reduction in costs for unplanned repairs, demonstrating the system’s effectiveness in handling minor issues before they escalate.
VII. Why CMMS EcoMaint is Ideal for Shipbuilding Enterprises
The shipbuilding industry, with its complex equipment and tight schedules, demands robust maintenance solutions. CMMS EcoMaint’s key strengths—comprehensive asset management, preventive maintenance automation, and real-time analytics—make it an ideal fit for VARD Vietnam. Its cloud-based accessibility and mobile app cater to the dynamic needs of a shipyard, while its integration capabilities ensure compatibility with VARD’s global systems.
Vietsoft’s expertise, demonstrated through over 300 successful implementations across industries like manufacturing, ports, and mining, ensures that EcoMaint delivers tangible results. For VARD Vietnam, this translates to a competitive edge in Asia’s shipbuilding market, where efficiency and reliability are critical.
VIII. Conclusion: A Milestone in VARD Vietnam’s Digital Transformation
VARD Vietnam implements CMMS EcoMaint as a strategic move to enhance its maintenance operations, reduce costs, and drive productivity. By leveraging Vietsoft’s advanced CMMS solution, VARD Vietnam is not only optimizing its current operations but also paving the way for a future-ready, digitally transformed shipyard. This project underscores Vietsoft’s ability to deliver tailored solutions for complex industries and reinforces VARD Vietnam’s position as a leader in specialized shipbuilding.
For enterprises seeking to modernize their maintenance processes, CMMS EcoMaint offers a proven, user-friendly, and cost-effective solution. Explore the CMMS EcoMaint solution here.
Contact us for consultation via hotline: 0986778578 or email: sales@vietsoft.com.vn.
