Introduction
Large integrated machine-building projects contain interfaces at numerous points. Interfaces between the scopes of different (sub)contractors, between the scopes of two or more colleagues each developing a sub-machine, or between disciplines such as mechanical, electrical, or hydraulic engineering. At MechDes, we see that interfaces require attention and care to prevent setbacks during construction and design.
In offshore and heavy machine building, everything revolves around quality, first-time-right delivery, and lifecycle reliability. The objective: preventing unforeseen delays, cost overruns, and unnecessary risks. Nothing is more frustrating than a large, post-processed, and costly welded frame that does not fit during construction simply because something went wrong at the interface between two parties.
Interfaces that are insufficiently aligned can also lead to major setbacks during the design process, especially when late-stage changes become necessary because a connection at an interface is missing or poorly coordinated.
For most readers, this may sound like a matter of simply "identifying and controlling interfaces," but reality is more complex. Interfaces exist at multiple levels and continuously evolve throughout the entire project. To illustrate this, we zoom in on an example: the design of a Subsea Rock Installation (SRI) vessel, where multiple machine builders and a shipbuilder collaborate.
Interfaces in Practice
In such offshore projects, the design process consists of concept, basic, and detail engineering phases. Boundary conditions are iteratively defined, and details become clearer as the project progresses. The same applies to interfaces. During these phases, numerous points require mutual alignment:
- Standard points: such as equipment mass, available space, space claims for secondary components (walkways, platforms, cabling, hydraulics, sprinklers), and ship motions causing accelerations.
- More complex points: such as the position of stiffeners or guides that run across multiple scopes.
- Design-specific points: for example, a machine carriage guide within our scope that continues into the shipbuilder’s scope and must be thoroughly coordinated.
These matters require intensive coordination through interface meetings, drawings, calculations, and 3D models. At MechDes, we have learned that exchanging 3D design models is powerful, but not without risks.
Common Pitfalls
A common pitfall in practice is that engineers sometimes check only a single operational position of a technical installation in their 3D model. This introduces risk. Machines are dynamic: they move, rotate, shift, or extend. Collisions in other positions, when discovered in later stages, can cause unnecessary delays and potentially additional costs.
To manage these risks, we organize interface meetings, exchange drawings and calculations, and conduct extensive interference checks. Crucially, we do not verify just one position, but all possible positions and operating conditions of the equipment.
For existing structures, we often use 3D scans as references. However, we never rely blindly on scans. Dimensional deviations or missing details can lead to costly errors. Therefore, we always conduct site visits to record and verify critical dimensions and environmental details. This integrated approach to using 3D scans has prevented multiple issues in our projects.
There is also the risk that internal scope divisions create additional interfaces. Colleagues focusing solely on their own part may lose sight of the broader system. We prevent this through internal design reviews in which engineers from different disciplines critically evaluate the overall picture.
From Concept to Detail: Interfaces Evolve Alongside the Design
Everyone involved in engineering is familiar with the phases: concept, basic, and detail engineering. What deserves emphasis is that interfaces follow the same iterative development as the design itself.
In the concept stage, interfaces are often abstract boundary conditions: "The equipment (e.g., a crane) on the vessel has approximately volume X, weighs approximately Y, and is positioned approximately at location Z." As the project progresses, details become concrete: "The exact geometry, precise weight, and forces introduced into the vessel, which must be transferred into the hull stiffeners."
Coordinating these interfaces requires a structured approach. In offshore and infrastructure projects, this typically includes:
- Interface meetings, where the shipbuilder and equipment suppliers share progress and open points.
- Exchange of drawings, calculations, and weights, ensuring loads, tolerances, and positions are verifiable.
- 3D models for interference checks, allowing all parties to assess the complete system together.
There is always a mutual responsibility to provide and verify information. Each party must not only share its own data but also actively confirm that the data from others has been correctly integrated.
For us, interfaces are not a side issue but a core aspect of effective project management. Thorough design reviews, interface meetings, and model checks are essential to controlling risks and ensuring project success.
Importantly, this is not only about systems and processes, but about the people executing them.
The MechDes Approach: Systematic and Integrated
Through years of collaboration and experience, first-time-right delivery has become central to our team dynamics. Colleagues apply their own expertise critically within a culture of transparency and healthy challenge.
During joint design reviews, these expert perspectives come together. We challenge one another, ask sharp questions, and combine insights to refine every design.
To safeguard quality throughout the project, we rely on the following principles:
- Interface identification: Starting in the concept phase, we map all interaction points and document responsibilities and boundary conditions.
- Technical verification: Exchange of 3D models for interference checks, multi-phase design reviews involving multiple disciplines, and simulations of all operational states including tolerances and deflections.
- Site visits and scans: For existing structures, we use 3D scans but always verify with on-site measurements to prevent costly dimensional errors.
- Collaboration and communication: Clear agreements from the outset regarding scope division and responsibilities, supported by active information exchange from all parties involved.
We differentiate ourselves by connecting multiple disciplines, taking responsibility, and always maintaining a holistic perspective. This is essential in projects involving dozens of stakeholders and hundreds of interaction points.
The MechDes Vision: Interfaces as the Core of Project Management
Interfaces are not abstract "risks" managed by lists and agreements. They are tangible interaction points that engineers address daily through design decisions. Seemingly small choices, such as verifying all operational states or not, determine whether a project runs smoothly or becomes filled with surprises.
When applied correctly, complexity is reduced to manageable proportions, and projects are delivered truly first-time-right.
"Interface management is not a formality; it is the backbone of success in complex machine-building projects. It controls risks, strengthens collaboration, and ensures projects are delivered first-time-right."
Our advice: collaborate intensively, combine expertise and knowledge, document agreements clearly, and continuously verify. In this way, interfaces become not only manageable but a differentiating strength that enhances the quality and reliability of every offshore and infrastructure project.
Meet Us at OEEC 2025
The offshore industry is continuously evolving, from increasingly larger installations to integrated offshore energy networks. This demands intelligent engineering, flawless collaboration, and an approach that aligns from start to finish.
At MechDes, we combine more than 30 years of mechanical engineering experience with in-depth offshore expertise. Our engineers and project managers translate complex interfaces and scopes into one integrated approach where technology, planning, and communication align seamlessly. That is how we deliver projects first-time-right: efficient, reliable, and high quality.
Curious how we collaborate with leading offshore partners? Or how our integrated engineering approach minimizes risks and accelerates project progress?
Visit us for a conversation with our project managers. We look forward to discussing your future offshore project.
Join us on November 25–26 at RAI Amsterdam, stand 1.409-1.
