Evolution of Lean manufacturing applied to shipping

Overview
The process of ship building has undergone a tremendous change in the past decades. Prior
and after World War 2, ships were built piece by piece. It was an era of joining parts by
riveting, most work being done in a shipway and an outfitting pier. The keel was first laid and
then ship construction took place from bottom to top.

This was followed by an era when welding techniques took over riveting and led to
fabrication of welded parts away from the shipways, Advancement in welding and cutting
technology leading to shipways being an area of assembly. This led to a shift from a shop
floor manufacturing to a flow approach in ship manufacturing. The flow approach of ship
manufacturing then looked at ways of increasing the productivity. This could be the period
between 1940 to 1960.

The era of 1960 to 1970 saw further changes. Different vessel types were being constructed
Larger & more specialized ship were constructed There was further advancement in
fabrication and welding techniques. Production flow techniques improved, simultaneous
growth in high technology induced cranes and transportation. There was a move towards
building of modules and pre outfitting concept came into play, where modules were
assembled.

Past 1970’s there was a collapse in demand for vessels, which led to better utilisation of
resources by the shipyard and moving towards the concept of lean manufacturing. The
fundamental philosophy behind Lean Manufacturing is to provide superior quality products
for more Customers at a significantly lower price and to contribute to a more prosperous
society.

• Completely eliminating waste in the production process

• To build quality into the process

• To reduce costs - productivity improvements

• To develop its own unique approach toward corporate management

• To create and develop integrated techniques that will contribute to corporate operation.

1965-1995: Japanese shipbuilders improved their productivity by 150%. They could achieve
tis on account of the following reasons:

1. Perfecting structural block construction approach

2. Developing advanced and zone outfitting
3. Applying lean principles
During World War II, Launching of the SS Samuel Gompers, a Liberty ship California
Shipbuilding Corp. shipyard at Terminal Island, in Los Angeles

Building of bulk carrier at Dubai Dry docks in 2011

Outfitting of a vessel at Dubai Dry docks in 2011

Focus question

1. Evaluate the principle of lean manufacturing after going through the readings
suggested in the module.
2. G through all readings suggested below. Carry out critical analysis of the various
shipyard production activities and devise a flow chart, which in your opinion is the
best possible ship production method. Support your answer with appropriate
illustrations.

Context

This is one of the core unit in the Master of Applied Science (Marne Engineering). It is
important that you have a fair idea in the operation of a shipyard and the ship building
process. This will help you in the role of a Marine Engineer both on board the vessel or
ashore in a shipyard or in ship management company.

Activities

You are advised to read the following readings available to you in the module to get a good
understanding of
the subject matter on lean manufacturing in shipbuilding,