Proceedings of the 2015 Industrial and Systems Engineering Research Conference

S. Cetinkaya and J. K. Ryan, eds.

Lean Shipbuilding for Project-based Manufacturing

Ge Jiang1,2, Dingzhong Feng2, Weihang Zhu3

1. Zhijiang College of Zhejiang University of Technology, Hangzhou 310024, China
2. School of Mechanical Engineering, Zhejiang University of Technology, Hangzhou 310014, China
3. Department of Industrial Engineering, Lamar University, Beaumont, Texas 77710, USA

Abstract
This paper presents an interdisciplinary process analysis to establish the lean shipbuilding system for project-based
manufacturing. According to the new requirements in ship design, construction process and lean management
proposed by the international shipbuilding convention and specification for shipbuilding enterprises, the 5W1H
method is applied to analyze the shipbuilding process. Combined with the ten construction technology capability
indices in the Shipbuilding Industry Standard Conditions Assessment by the Ministry of Industrial and Information
Technology of the People’s Republic of China, this interdisciplinary analysis covers production plan, manufacturing
processes and logistics management. This paper further discusses key system technologies including value stream
analysis, lean shipbuilding task decomposition, lean shipbuilding project management, lean shipbuilding precision
management and full factory management. A case study in China shows that by using the proposed methodology,
shipbuilding production plan can be efficiently customized based on project-based manufacturing characteristics.
Lean shipbuilding has great potential in significantly improving productivity and reducing lead time in shipbuilding.

Keywords
Lean shipbuilding, 5W1H, project-based manufacturing

1. Introduction
In the recent years, a series of new international shipbuilding conventions, rules and standards have been introduced.
These include Ship Energy Efficiency Design Index (EEDI), Hong Kong International Convention on Safety and
Sound Recycling of Ships, Ship noise level rules, IMO Goal-based ship construction standards (GBS) and IACS
Common Structural Rules for Coordination (CSR-H). They put forward higher requirements in ship design,
building, technology, lean management, materials and equipment. As a result, structural change has occurred in the
market demands. Green, energy saving, environmental protection, and safety have become the trends in the industry.
The major shipbuilding countries are all improving technology innovation capabilities. They wish to establish the
competitive advantage and take the lead against the competitors by raising the technology bar.

In 2013, shipbuilding industry, together with steel, cement, aluminum and plate glass, are listed as the top five
overcapacity industries in China. In order to speed up the restructuring and technological upgrading, China Ministry
of Industry and Information Technology published Shipbuilding Industry Standard Conditions assessment rules in
November 2013 [1]. Based on the general requirements of the current shipbuilding industry restructuring /
upgrading and resolving contradiction of overcapacity, the standard proposed standardization requirements for the
shipbuilding companies in seven areas, including basic conditions, production facilities, equipment and quality
measurement, construction technology, technological innovation and products, personnel, quality assurance system,
production safety, environmental protection, occupational health and social responsibility. It establishes a bulletin
system for the companies that meet the technology, environmental, energy saving and safety standards. It serves as
the basis for the relevant local and national policies. It guides the community resources to the elite shipbuilding
enterprises that meet the Standard Conditions. It imposes differentiated policies for those not meeting the Standard
Conditions and without new shipbuilding orders for over one year. It encourages enterprises to improve and perfect
the production conditions.

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