Objective:
Implement and measure the results of Five S methodology at two repair yards, Todd Pacific and Atlantic Marine, while creating a shipyard-focused implementation program to assist U.S. shipyards in implementing Five S programs quickly and effectively.
Summary:
NSRP’s Five S project exhibited immediate 30 percent productivity improvements in pilot tests at Todd Pacific Shipyards, leading both Todd and Atlantic Marine to accelerate implementation throughout their shipyards. Long-term productivity results are expected to be at least 10 percent from Five S alone. “The Five S program is really being used as our first initiative at applying Lean Enterprise concepts to ship repair,” said Camilla DiBarra, Five S coordinator at Todd. “It has become our vehicle for changing the culture of the shipyard.” Originally a Japanese acronym, Five S has various translations in U.S. manufacturing environments, but the basic ideas are the same: Sorting, Simplifying, Systematic Cleaning, Standardizing and Sustaining. Five S as a stand-alone project will significantly decrease costs, but when paired with Lean manufacturing efforts, it can have a much higher return. Support for Five S permeates Todd Pacific from Pipe Quarterman Fred Frankenberg to CEO Steve Welch. “It makes my job easier,” Frankenberg said of Five S. “It used to take a day to get everything ready to ship out to a boat to perform services. Now I give a list to a guy, and it’s out on the pier in a couple of hours.” Todd Pacific and Atlantic Marine completed additional Five S workshops above and beyond the scope of work within their shipyards. A guide to implementing Five S in shipyard environments is available from V2R Consulting Group and is based on these two shipyards’ experiences.
Final Report – Approved for public release; distribution is unlimited
Overview
Project Team:
- Vigor Industrial
- Atlantic Marine
- V2R Consulting
March 2000 - September 2001
NSRP ASE Investment: $466K
Industry Investment: $772K