Identification of waste for shipyard through lean manufacturing approach

Abstract

Shipyard is a specialized facility equipped with various tools to support the process of building, repairing and maintaining ships. There are several types of variant ships, such as military ships, tourist boats, cargo ships and passenger ships. Apart from being a place for shipbuilding, shipyards are utilized to conduct several activities, such as ship design, equipment installation, plate installation, feasibility tests and classifications. There are many production activities and production flows that allow for potential waste problems that have an impact on labor usage, product quality, costs, and production time. The aim of this research is to identify waste in shipbuilding production lines through a lean manufacturing approach. The lean manufacturing approach is one of the ways in shipyards to observe the level of waste in the production process, so that it can reduce unnecessary activities in the production process which can increase production efficiency and effectiveness. This study approach begins with the identification of waste in the production line through mapping on each line so that activities that have no added value are identified. Based on the results of identification using the waste assessment model (WAM) method which consists of a waste relationship matrix (WRM) and a waste assessment questionnaire (WAQ), waste is obtained namely inventory (27,20%), overproduction (20.24%), defective products (20.04%), motion (12.47%), transportation (9.23%), waiting time (7.46%) and process (3.37%).