Lean Shipbuilding Theory and Practice in Foreign
Lean Shipbuilding is to build China's shipbuilding industry an effective way to modern shipbuilding. This systematic analysis based on the concept of Lean Shipbuilding illustrate Lean Shipbuilding technology system in order to case-study method to study the theory of lean shipbuilding shipbuilding industry in the U.S. and Japan the effectiveness and future development trends, Finally, China's implementation of the Lean Shipbuilding relevant measures and suggestions.
Lean production model from the Japanese auto industry's summary, Toyota Motor Corporation is a typical representative of its core idea is to eliminate the production of waste and all non-value-added chain, the enterprise also has mass production economy and variety of production flexibility capacity.
Lean Shipbuilding derived from the concept of lean production is lean production theory in ship Industry, first proposed by the U.S. shipbuilding industry, shipbuilding contract, that contract from the beginning to the delivery of the ship completed the construction of the entire process, through motivation and mobilization of all employees to continuously improve and perfect the process of shipbuilding, ship construction to reduce all the waste, to reduce the shipbuilding cycle, reduce shipbuilding costs and improve shipbuilding quality.
U.S. shipbuilding industry that, while Lean is Toyota's conclusion from this particular environment, but its ideas have been sublimated to the philosophy and principles of the height of the basic theory, that is, in the shortest possible time, with minimal waste produced customers need the products, applicable to any manufacturing process, both for mass production, or customization, have guidance, but also a matter of course for the ship industry.
At the same time, shipbuilding industry and some differences do exist between the automotive industry, has some unique features, such as the products are always after the construction of the first order; ship construction process with manufacturing (Production) and Construction (Construction) of the double feature ; ship construction cycle long. In order to be able to successfully apply lean production theory the United States shipbuilding industry, ship building capacity and improving the United States Merchant international competitiveness, the United States in 1999 established the National Shipbuilding Plan (NSRP), and in its main program - advanced shipbuilding business plan (ASE ) established the Lean Shipbuilding meter-k1J (Lean Shipbuilding Initiative, LSI), in order to achieve more success for those who wish to accelerate the transition to lean production, improve the learning curve of shipbuilding enterprises to provide a shared platform (see Figure 1) .
Specific research projects, the Lean Shipbuilding program has funded eight research projects. The research focused on expanding the value chain based on lean production techniques in the shipbuilding industry applications, based on rapid response to market demand, lean management, 5S theory application in shipbuilding industry and the training of lean manufacturing simulation, in which the first two directions, ASE investment in larger, respectively, 8.69 million U.S. dollars and 729 million.
In the specific results achieved in 2005 by the British "MI on the basis of the U.S. shipbuilding industry capacity assessment results, Lean Shipbuilding plans to ship over the past five years, the United States to upgrade industrial capacity played a great role. Such as value stream mapping method used repair process of U.S. non-manufacturing value chain to be confirmed, to take relevant measures to eliminate the waste of the production process, through the implementation of pilot projects to enhance the learning curve; the early effects of lean project extended to the entire U.S. shipbuilding industry, for the elimination of waste provides a new solution; on the client / transfer process between the shipyard was evaluated to eliminate such as inspection, testing and other non-value added sectors; as the best shipbuilding practices shared throughout the industry to provide a material. on specific the cost-effectiveness, the statistics show that since 1999, the U.S. shipbuilding industry cost savings of some 377 million U.S. dollars, half of which results thanks to Lean Shipbuilding plans.
To further expand the application of lean shipbuilding research, FM) in its assessment concluded with the recommendation to increase the investment aspects of lean production.
1. Shipbuilding industry to implement the main elements of Lean Production
Specific to the operational level, Lean Shipbuilding mainly include: value stream management, lean production management, lean quality management, a smooth production process management and lean enterprise culture building (shown in Figure 2).
At the technical level, including: value stream analysis, supply chain and logistics, customer relationship management, balanced production of rhythm, single-piece flow techniques, pull-type production technology, precision control, process control, standardization of systems, reasonable production layout, full production maintenance, ergonomics and safety, procurement costs, design costs, production costs and logistics costs, people-oriented, work teams, flatter organizations.
(1) Value stream management
Value stream is to make a specific product by any business when the three critical management tasks necessary for a specific event. These three tasks are: from concept ideas through detailed, to the entire process of production tasks in problem-solving; from accepting orders to draw up a detailed schedule, to the delivery of the whole process of information management tasks; made from raw materials to the final product, delivered to the user in the hands of the whole process of material transformation task.
Value Stream Mapping refers to finished products from raw materials to all activities (value-added and non value-added of two) expression (Figure 3),
The process includes both information flow also includes logistics, is the key to the implementation of lean production. As all business processes (information flow, logistics) to achieve an effective visual tool for identifying the value stream through the various types of waste, and they take appropriate measures to improve the process from a global perspective.
In the traditional shipbuilding mode, non-value added activities is far greater than the time value-added time. Lean Shipbuilding model to focus on reducing non-value added activities to reduce production cycle times, greatly reducing the waste of intermediate links.
(2) Lean Production Management
Lean production management, including lean production planning, lean production processes and on-site management of content, is the core of lean shipbuilding.
In the preparation of production plans need to pay close attention to the production process of synchronization and equalization of production requires the use of group technology principles, rational design of single-piece flow production operations amount to calculate the production step (Figure 4).
Management in the production process to achieve JIT production, one-piece flow process and pull planning system. Let each part be continuous and intermediate products produced according to customer (internal and external) requirements to complete production on time, not early, not delayed, the implementation of zero inventory management and reduce overproduction.
In the lean-site management, the establishment of "three to" on-site management system, that is, production workers as the main active service in various support staff on site; to workshop director led unified command in the field coordination departments to provide timely quality around the plant site services; to the scene as the center, asked all staff to focus and concentrate on the scene, equipment maintenance personnel for field garrison. In particular, on-site management of the 5S management, the implementation of the most significant effect.
(3) Lean Quality Management
Lean Production in the quality management view is that "quality is created, not check out." In accordance with the requirements of lean production, quality assurance functions should be transferred to the operator, to implement quality control procedures, to achieve total quality management. In the shipbuilding precision control, personnel quality and error prevention measures are strict. In which precision control is Lean Shipbuilding Shipbuilding important feature is the method of mathematical statistics, shipbuilding production process by the processing tolerances and precision welding thermal deformation control volume instead of margin with the compensation approach to reduce the shipbuilding process, assembly and welding were invalid work.
(4) a smooth production process management
For shipyard production is always in a stable state, both need to standardize operations, but also a reasonable production process, a reasonable production layout, ergonomic work environment and full participation in factory management and cultural environment.
(5) Lean Enterprise Culture
Lean production approach emphasizes the realization of human potential, it is necessary indoctrination of lean production to the hearts of every employee. Each employee at work not only to carry out orders, more importantly, active participation, play the role of decision-making and decision support. Through team work, the suggestion system, quality control group, target management and a series of specific measures, mobilize and encourage the workers to "creative thinking" and focus on training and training workers and managers at all levels in all aspects of skills to maximize and use of business organizations in the potential of every individual, improving their enthusiasm and interest.
2. Foreign shipbuilding industry case study of lean production model
(1) Lean Shipbuilding Northrop Grumman Ship Systems Theory to Application
Northrop Grumman Ship Systems (NGSS) as a world-renowned shipbuilding company, not only bear the U.S. Department of Defense military ship construction tasks, while the field in the merchant has a good reputation. In recent years, NGSS the acquisition of a number of shipyards and related supporting institutions based on the plan through the implementation of lean enterprise integration within the Group.
Under the guidance of lean principles, NGSS the whole process of ship construction in the implementation of "creation and orderly place to work, from the perspective of customers determine the value and eliminate non-value-added chain, to create the production flow from the customer pull" principle, the maximum degree of details on the lean practice.
Specific lean practices, NGSS completed by Northrop Grumman Integrated Systems, Lean management pilot project led, and then promoted successively A Fondahl shipyards, Ingalls shipyard shipyards and 绾芥柉娉㈢壒绾?Williams to lean production practices, including the production sector, management and other support departments, including all sectors, all processes are taken to eliminate waste, improve processes, optimize the operation of the lean initiatives.
As of 2003, the lean implementation plan to achieve the desired effects, such as shortening the waiting time of 57% and 41% of the production completion time, a decrease of 75% of staff travel time; average production cycle reduced by 50%; production of 41% inventory reduction ; costs are effectively controlled, the financial effect to more than 10% per year increase.
(2) Lean Shipbuilding theory of General Dynamics Electric Boat in the application of
By military needs and competitive environment, Electric Boat (EB) from the end of last century began the process of improving the movement was launched in order from the production cycle, cost, quality and customer demands, and so enhance their core competitiveness. As one of the most important as a means and tools of lean production strategy in 2002 was the introduction and widespread implementation of Electric Boat.
Electric Boat to take specific measures include: (1) strengthen the training, awareness raising; (2) implementation of the 5S management, create a visual workplace so that more clean workshop, organized to improve the quality of staff; (3) stress beat production on the basis of production time; (4) the implementation of Poka-Yoke error correction method.
Through the implementation of lean initiatives, Electric Boat's competitive advantage has been greatly enhance the: (1) to increase production, reduce the control interval; (2) visualization of the entire process operation is conducive to the attention of employees gathered at the same time within鍜屽閮ㄩ【瀹㈡弧鎰忓害鏂归潰;(3)宸ヤ綔鍦烘墍鐨勯珮鏁堢巼鍜岀敓浜ф祦绋嬬殑鏃犲樊閿欍?鍙娴嬫?浣胯埞鍘傚熀鏈笉浼氬嚭鐜扮揣鎬ユ剰澶栵紝浠庤?鍙互瀹炵幇杩滆窛绂昏鍒掓帶鍒?(4)闄嶄綆璁捐涓庡缓閫犳垚鏈紝缂╃煭娼滆墖寤洪?鐢熶骇鍛ㄦ湡銆?br />
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銆??鑷敼闈╁紑鏀句互鏉ワ紝鎴戝浗鑸硅埗宸ヤ笟瀹炶返绮剧泭鐢熶骇澶ц嚧缁忓巻浜嗕竴涓湁瀹炶返浣嗘棤鎰忚瘑鈥斾釜鍒簿鐩婄敓浜у師鐞嗗簲鐢ㄢ?鍏ㄩ潰鏈夋剰璇嗗疄鏂界簿鐩婄敓浜х殑杩囩▼銆傜洰鍓嶏紝绮剧泭閫犺埞鐞嗚鍦ㄤ腑鍥介?鑸圭晫宸茶幏寰椾竴瀹氱▼搴︾殑璁ゅ彲锛屽悇閫犺埞浼佷笟鍧囦笉鍚岀▼搴﹀湴瀹炴柦浜嗙簿鐩婄敓浜с?鍚屾椂锛屼綔涓鸿埞鑸跺伐涓氬綊鍙ｈ鏀跨鐞嗛儴闂紝鍥介槻绉戝伐濮斾篃鍙峰彫鍚勯?鑸逛紒涓氬疄鏂界簿鐩婄敓浜э紝鎻愰珮鏁堢泭銆?br />
銆??浣嗕粠绮剧泭鐢熶骇妯″紡鍦ㄦ垜鍥借埞鑸跺伐涓氬疄鏂借繃绋嬫潵鐪嬶紝浠嶅瓨鍦ㄥ涓嬩笁涓柟闈㈢殑闂:鍚勯?鑸逛紒涓氳櫧娑夊強绮剧泭鐢熶骇鐨勭浉鍏冲唴瀹癸紝浣嗕笉澶熺郴缁?鐮旂┒闃熶紞瓒嬩簬鑰佸寲锛屽紑鏀炬?涓嶅;鏀垮簻鐩稿叧鎶曞叆鏈夐檺锛岀簿鐩婇?鑸圭爺绌舵湁寰呮繁鍏ャ?
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銆??(2)娉ㄩ噸绮剧泭鐢熶骇鐞嗚鍦ㄨ埞鑸跺缓閫犲墠绔竴涓?綔涓氬垎瑙ｉ樁娈电殑搴旂敤锛屽鑸逛綋銆佹爾瑁呭拰娑傝涓夌浣滀笟鍒嗚В鐨勭敓浜ц妭鎷嶅繀椤绘弧瓒冲潎琛¤繛缁殑鍑嗘椂鐢熶骇;
銆??(3)娉ㄩ噸绮剧泭鐢熶骇鐞嗚鍦ㄨ溅闂村眰闈㈢殑璇曢獙锛岄?杩囦环鍊兼祦鍥鹃?鎷╁疄鏂藉璞★紝缁勫缓绮剧泭鐢熶骇瀹炴柦鍥㈤槦锛屽湪绮惧績鍑嗗鐨勫熀纭?笂锛屽椤圭洰杩涜鍏蜂綋瀹炴柦;
銆??(4)鍦ㄩ」鐩疄鏂藉悗锛屽缓绔嬬簿鐩婇?鑸圭淮鎸佸皬缁勶紝鍦ㄥ珐鍥烘垚鏁堢殑鍩虹涓婏紝鏈潃绮剧泭姹傜簿鐨勭簿绁烇紝鎺ㄨ繘鏂伴」鐩疄鏂姐?(鑸硅埗 绗?54鏈?2006骞?鏈?
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