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Bringing the sail-making operation closer to the boats rather than transporting the sails to the workshop: that?s the principle behind the system North Sails has implemented at Les Voiles de Saint-Tropez. Since 2018, a tent with a 250 m² floor area has served as a repair facility upon the boats? return from regattas. Up to six master sailmakers can work there, sometimes through the night.
When the sailors come ashore, the sailboats take their watch
The sun is setting over Saint-Tropez. The boats are returning to the docks, and the crews are heading off to debrief on the regatta?often over a few drinks. Under the North Sails tent, another day is beginning.
The first damaged sails arrive directly from the boats. They are unrolled, inspected, and then repaired on a work surface set up right next to the docks. Since 2018, North Sails has been setting up this temporary workshop during Les Voiles to provide on-site service and, whenever possible, avoid transporting sails to the permanent loft in Fréjus.
The idea is simple: save time. A sail that?s taken down in the late afternoon needs to be ready first thing the next morning.
Paul Williamson, the program manager, explains this service to us: " Some of the sails they handle can be as large as 1,200 m². The team consists of six master sailmakers, five of whom can work simultaneously on the floor. All are experienced: at night, they must be able to assess the situation and quickly decide on the necessary course of action."
Between 60 and 80 sails in a week
Spinnakers account for the bulk of repairs. Lightweight and subjected to heavy stress during maneuvers, they can be damaged even in light winds. A spinnaker that snags on a spreader while being hoisted or lowered is enough to keep a sailing crew busy for several hours.
Paul estimates that a typical week involves processing between 60 and 80 sails. But the workload remains highly unpredictable.
" "We start around 4 p.m., and after that, there's no set end time," he summarizes.
When they arrive, the repairs are estimated in terms of labor hours. The team then compares this estimate to the time remaining until the next day. One night may be relatively short. Another may end in the early morning.
When the workload exceeds the team's capacity, priorities must be set. Some repairs may then be postponed by a day or two.
Proximity Saves Time
That's where the setup at the port really comes into its own. Without a temporary workshop, the sails have to be loaded, transported to the sailmaker's, unloaded, and then sent back the same way once they've been repaired.
By bringing the master sailmakers closer to the boats, North Sails reduces these handling steps and, above all, saves time. Contact with the crews is also immediate: a sail can be inspected just a few minutes after it is unloaded.
A tent is no substitute for a permanent loft and its equipment. It serves a different purpose: to provide repair capabilities as close as possible to the fleet during the regatta.
Early in the morning, the repaired sails are taken back to the boats. A few hours later, they?re back on the water. And come evening, the dock awaits the next batch.
