Research and Implementation of Lean Production Mode in Shipbuilding

Abstract

This paper studies the production process of a shipbuilding enterprise. The company suffers from long manufacturing cycle, low utilization rate of personnel and an unbalanced production line. To solve these problems, the lean shipbuilding mode, mainly divided into shipbuilding work breakdown, production plan and virtual flow operation in this paper, is put forward, which combines the lean production and modern information management technology with shipbuilding. Supported by the theory of work breakdown structure and task package scheduling, the shipbuilding task package is reasonably divided. The priority of task package manufacturing is determined by calculating the task package manufacturing sequence coefficient, and a reasonable number of operators is calculated to ensure the continuity of segmented manufacturing. After determining the manufacturing priority of the task pack and the number of allocable personnel, the corresponding work can be scheduled. Production planning drives all production activities of the shipbuilding enterprise, and just-in-time production is achieved through the reasonable arrangement of these production plans, thus reducing the waste of personnel and time. Then, the virtual flow operation is carried out, which can achieve high efficiency of flow production and high flexibility of fixed workstation production during the production process of large-scale and heavy-duty products. The virtual assembly production system of the workshop is established according to the characteristics of shipbuilding operation and the actual production situation. On this basis, a lean shipbuilding manufacturing execution system for small and medium-sized shipbuilding enterprises is developed to achieve lean production in a shipbuilding workshop. Through the implementation of the lean shipbuilding mode based on task package scheduling and its manufacturing execution system, compared with the original data, the ship production cycle is reduced to 76.7%, the number of workers is reduced by 16.7% and the production balance rate is up to 81%.