Engineering & Construction – Shipbuilder
Operational performance improvement
“The lean programme has proved a key enabler in our objective of becoming the first UK warship yard to achieve world-class manufacturing status. The success of the programme has led to the roll-out of Lean to our other shipyards. This is a major step forward in improving our manufacturing processes to a standard associated with the aerospace/ automotive sectors. As a result it will deliver higher quality products at a lower cost to our customers.”
-Client Managing Director
Approach
- Developed a high-level, future state Operations Architecture based on Lean Manufacturing principles.
- Rapidly deployed selected elements of the new Operating Architecture in order to achieve early benefits.
- Rolled out the new architecture, processes and tools to all facilities across three shipyard operations.
Business Challenge
Design, develop and implement a radical, new operations architecture based on Lean Manufacturing principles.
Background
- Manufacturing operations had undergone significant changes transitioning from submarine programmes to surface vessel contracts.
- Funding for the programmes introduced new cost pressures and constraints, and the company needed to improve manufacturing operational efficiency and achieve planned programme milestones.
Key Achievements & Value Delivered
- One of the most ambitious programmes of its kind in the industry, it has also been recognised as one of the most successful.
- 23% Productivity improvement leading to targeted savings of £46m over a 10 year period.
- Lead-time reductions of up to 50% in some areas.