8 4 DES IGN PERSPECTI VE LEAN interior outfitting LEAN planning streamlines onboard interior outfitting projects to deliver higher quality at a lower cost I began developing the stateroom/suites LEAN Train System with Porsche Consulting in 2011 after starting my first project for Royal Caribbean Cruises Ltd. in 2010. That project was planned as a minor refresh of 1,029 cabins, at a rate of 40-45 cabins per day in a four-week dry dock. By 2014, I was able to use the LEAN system to refurbish 1,560 staterooms and suites in 21 days with six ‘trains’ working on different scopes. This increased efficiency by 150% and resulted in much better quality, less stress for the workers and lower costs than would have been achieved with conventional project planning. Makinen, the contractor involved in the development of this refit, still plans most projects using the LEAN Train System. LEAN construction has four principles: flow, takt, pull and zerodefect. It also adheres to the five ‘R’s of just-in-time delivery: the right part, in the right quality, at the right time, in the right quantity, at the right place. Efficiency is ensured by eliminating waste rather than increasing performance, following LEAN production principles throughout: analyse all activities; seek value-added activities; analyse and eliminate waste and replace it with value-added activities; and align and link valueadding activities, tasks and information. Detailed planning is essential so that, just like a good rowing team, everyone is working to the same rhythm. Best results are seen in highly repetitive work areas, such as staterooms. For contractors and owners, LEAN outfitting entails a learning process and development costs, however these will be paid back during subsequent projects. LEAN projects can also require a slightly bigger team of workers to cut costs and execution time. LEAN projects boost customer satisfaction through higher quality, speed and control, clear start and stop dates and more accurate cost planning. They ensure excellent coordination with other areas in the ship and reasonable re-planning time in case of unexpected interference. And we’ve seen a tremendous decrease in worker stress levels because they have clear and achievable goals. CFI Daniela Herget is the owner of Cruise Quality Consult Daniela Herget: Cruise Quality Consult Lean production ensures efficiency by eliminating waste
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