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.”

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.
Client Managing Director

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.