Identifying the Shipyard Waste: An Application of the Lean Manufacturing Approach

Shipyard is a specialised facility equipped with various tools to support the process of building, repairing and maintaining ships. There are several types of variant ships, such as military ships, tourist boats, cargo ships and passenger ships. Apart from being a place for shipbuilding, shipyards are utilised to conduct several activities, such as ship design, equipment installation, plate installation, feasibility tests and classifications. There are many production activities and flows that allow for potential waste problems that impact labour usage, product quality, costs, and production time. This research aims to identify waste in shipbuilding production lines through a lean manufacturing approach. The lean manufacturing approach is one of the ways in shipyards to observe the level of waste in the production process to reduce unnecessary activities in the production process, which can increase production efficiency and effectiveness. This study approach begins with identifying waste in the production line through mapping on each line so that activities with no added value are identified. On the basis of the results of identification using the waste assessment model (WAM) method, which consists of a waste relationship matrix (WRM) and a waste assessment questionnaire (WAQ), waste is obtained, namely inventory (27,20%), overproduction (20.24%), defective products (20.04%), motion (12.47%), transportation (9.23%), waiting time (7.46%) and process (3.37%)