Lean IHOP Transformation of Shipyard Erection Block Construction

Abstract

The modern system of shipbuilding includes applying integrated hull construction, outfitting and painting (IHOP) of ship interim products, as opposed to the traditional manner of first constructing the hull blocks, then performing basic outfitting and finally painting, all separate of each other. Even though most shipyards apply some degree of integration of all trades during vessel construction, much work could still be better integrated. This paper analyzes and maps the present IHOP construction of a typical shipbuilding erection block in a real shipyard. Through the application of a Product Work Breakdown Structure (PWBS) and group technology, the degree of IHOP integration could be increased. This is demonstrated to be in compliance with the lean principles of improving flow and kaizen. The paper will suggest how the vessel construction could be become leaner through a value stream map, thereby decreasing both duration time and man-hours thus securing significant savings for the shipyard.

PWBS Best Practice Analysis of Two Shipyards

“…Value stream mapping methodology has been demonstrated to aid in improving panel assembly process [8,9], the built-up panel assembly process [10,11] and the large block erection process [12]. However, the purpose of this paper is to determine and demonstrate how the PWBS of two shipyards should be compared, and the one with the best system should be adopted by the other.…”