Scaling a Shipbuilder: How One Business Grew Revenue by 74%

Problem

A shipbuilding and ship repair business located in regional New South Wales, had ambitious goals to scale operations, increase productivity, and revitalise Australia’s marine manufacturing sector. Despite its “can do” reputation, the company faced several growth challenges:

Limited capacity to service multiple vessels simultaneously due to aging infrastructure.
Need to increase workforce and upskill employees to support expansion.
Decline in skilled tradespeople in the marine industry.
Gaps in digital tools, systems, and market positioning.
A desire to enter new markets, increase exports, and pursue strategic partnerships.

To meet these challenges and transition from a medium to a larger-scale manufacturer, the shipbuilder required a strategic roadmap for sustainable growth, operational refinement, and infrastructure development.

Solution

Working with the shipbuilder a tailored strategic roadmap was designed for implementation. The plan identified key threats and opportunities, aligned strategic goals, and built operational capacity.

Key initiatives included:

Facility Modernisation: Company refurbished its 2,500-tonne slipway, reinforced structural integrity, and built a new travel lift section to future-proof capacity for larger projects.
Strategic Infrastructure Investment: Commissioning of a 450-tonne travel lift to enable concurrent repair and new build projects.
Capability Development: Targeted workforce expansion and skills development, including new apprenticeships and upskilling of existing staff.
Digital and Market Enablement: Engaged third-party partners to redevelop the company website and prepare online booking capabilities.
Program Integration: Accessed grant funding support for R&D and graduate placements, boosting tooling, inventory, and manufacturing workflows.
Environmental Innovation: Prepared for the launch of new ship technology, a specific R&D initiative aimed at reducing global shipping emissions and environmental contaminants.

Outcomes

Company achieved significant and measurable success:

Revenue Growth: Sales revenue increased by 74%.
Workforce Expansion: Full-time employees increased from 55 to 80, with a further 50 planned.
Export Growth: Export revenue grew to $100K.
Profitability: EBIT margin improved by 9% over the previous year.
Capability Enhancement: Improved cash flow, tooling systems, maintenance scheduling, and digital marketing capability.
Strategic Positioning: Positioned the company as a key player in the national marine repair and shipbuilding market, attracting complementary businesses to the precinct.

Return on Investment

$50K Grant funding enabled high-leverage business planning and operational improvements, and supported graduate placements and advanced R&D.
EBIT margin +9%;
Sales revenue +74%;
Export revenue increased to $100K
Full-time equivalent (FTE) headcount up by 25, with more in the pipeline

This company’s journey exemplifies how regional manufacturers can scale sustainably with the right strategic support. If you’re looking to transform your business, grow exports, or invest in regional capability, Stoke Consulting can help you build a strategic roadmap for measurable success.