Lean Maritime

Lean Management at KAEFER
Pilot Project: Brazil

Project overview
November 2013
This document is confidential and is intended

for exclusive use of KAEFER. All content is
property of Lean Maritime GmbH.
LEAN MARITIME
1. Initial situation
2. Management summary
3. Analysis & implementation results
LEAN MARITIME
KWS1301_PRES_131025_1_PEL_Presentation Brazil.pptx
Initial situation and objectives
The refurbishment of the accommodation block

on offshore on the current contractual scope is
a relatively new field for KAEFER Isobrasil
Identify and quantify waste in all areas of the

project focusing on quality, cost, lead time and
safety
The project management and execution teams

are not very experienced, despite the inclusion
of some experienced workers from other
companies (e.g. ex Pontec)
Develop and test improvement ideas, quantify

potential savings
A broaden spectrum of activities from metal

works to flooring, electrical, piping and furniture
is covered
P32 was identified as a pilot project; further
units will follow with a total volume over 5 times
the current one
A good delivery on P32 opens the doors for a
long term relation with Petrobrs (40+ units)
Define and deploy improved planning and work

standards on P32 to be transferred to other
sites
Introduce the project management and
execution team to the lean principles and
methods
Enhance team acceptance and drive for
continuous improvement
Demonstrate to Petrobrs KAEFERs superior
performance and commitment to improve
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Management summary
Master Schedule with mainly parallel works increases personal needs and enhances the management
complexity;
The work content on each area is not always clearly defined / known and generates uncertainty on
board during execution; drawings quality is poor (missing / wrong information frequent)
No specific work preparation done on board for the current or upcoming activities; fire-fighting is
preferred to fire-prevention; preparation of materials done after the beginning of the task, without
previous preparation;
Tasks given daily to workers without a systematic alignment with task duration; over-manning
frequent; work content of a few hours given as daily tasks
Required tooling for the jobs is often not available / not sufficient or not ideal for the task;
Installation methods not well defined or standardized; each team member decides how to perform
the task on the moment;
Workers generally motivated and willing to work; lack of defined targets, poor organization and
reduced focus on performance management leads to various types of waste
Management spends considerable part of their time generating reports (internal and for Petrobrs);
while at the installation area, main focus is how to keep people occupied with something, even if with
meaningless activities; not used to see/act on waste; generally open for change.
Know-how level of team leaders below ideal; support from land required; access to information and
communication with land sub-optimal (no email/internet connection, restricted communication)
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Scope of analysis
Definition of work
content on each area
Preparation of material
lists
Preparation of
technical and assembly
drawings
Loading of containers
@ KAEFER Maca
Definition of material
requirements
Definition of tooling
and estimated work
content
Coordination of
transport to Petrobrs
Communication of
delivery dates with
execution team
Verify specification,
drawings and material
availability
Define ideal work
sequence
Prepare work
authorization
Assign team to activity

based of personal
competences and
experience
Execution of activity
Clean and organize
area upon finish
Measure work
advancement
Coordination of returns
of containers
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Areas for improvement on the engineering process
Work content in each area not clearly defined / missing parts e.g. smoke
alarms, etc
Define engineering content check-list / questionnaire
Create room-book with all work content for each room
Definition of work
content on each area
Preparation of
technical and assembly
drawings
Definition of material
requirement and
workload
Definition of best
possible technology
Dimensions missing on drawings; Drawings printed out of scale;

Define drawings content standards; introduce control loops
lists
based of personal
availability
competences and
Required materials to complete each activity not entirely
defined / not always
experience
@ KAEFER Maca
Define ideal work
known (e.g. what / whether insulation to install, etc)
sequence
Coordination of
Create room-books with information about all materials to be installed;
transport to Petrobrs
Prepare work
Clean and organize
Create material packets
and control loops;
authorization
area upon finish
Communication of
delivery dates with

Communicate
execution
conclusion
Workteam
content estimation not existent / not accurate enough
Coordination
returns
Plan of
work
and manning based on work content and performance values
of containers
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Analysis
Measurement of
room interior
Check room
content / spec
Create detailed
room book and
installation
drawings
Install and
improvise !
Measurement of
room interior
Check room
content / spec
Create preliminary
room book and
generic drawings
Demolish the
existing room
Detail
measurement of
existent behindthe-wall installation
Complete Roombook with as-built

detail drawings
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Examples of drawings
Analysis
Guess
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10
Common problems on drawings
Examples
Some dimensions systematically missing (e.g. position of lights,

switches, furniture, etc)
Position of components referenced to elements that are not
installed when the dimension is required
Materials and equipment lists not included or not complete
Customer complaints over drawings and dimensions problems
A new set of rules and a quality control loop procedure were defined
with the design office implementation started
REGRAS DE COTAO
Dimensional quotation rules
Include room size dimensions on all drawings
General
INTERNAL CONTROL BOARD

Drawings prior emission
Introduzir eixo da baine e colocar cota de

barra de contencao emArea
relacao aos eixos
Project
Docum ent num ber & title
Perfis no solo
Recipient
Client
Site
posicao da contrapara em relacao aos eixos ou a barra de contecao
Contrapara
OK
rem arks
Validated by
Is the print correct? Size + view
Forro
Posicao do altofalante e HVAC difusor

Is the format adapted to the project? Prancha
Posicao do corte da luminria
Elctrica
posicao dos interruptores, tomadas (contrapara) - cotacao em relacao a antepara

Impression size is indicate
luminaria - cotacao em relacao a antepara X; Y
Language adapted to project
Scale is indicated
Title complete
Hidrulica
Mobilirio
General
HVAC
Revision
Date of realisation
Names of the persons involved (redactor ---> validator)
Inteoduzir posicao do mobiliario que naoDocument

est contra
a contrapara
status?
(for info/for valid./for construction/as built)
Cabides, accessorios banheiros
Logos
Posicao e altura de accessorios - possivel adicionar H:xx para altura
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Number of pages
Isolamento
11
Information quality in isometrics
Workshop
A new tool was introduced to calculate the length of

pipes to be cut based on isometric
The customer standard for generation and provision
of isometrics will be recovered and used to train
the engineers (today is unknown by them)
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12
Wet-unit profiles
Workshop
The real position of the wet unit

depends on the ship bulkheads;
these are not visible at the time of
drawing, therefore it is not possible
to use as reference
1. Dimension position of wet unit to

middle line of cabin
2. On board, once the old wall
panels are removed and floor is
finished, measure and mark
center line of room 10
minutes activity
3. Position wet unit 10 minutes
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13
Kick-off visit on board
Workshop
Check list for room content

(e.g. remove insulation (yes/no) and type)
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14
New technologies
Workshop
XYZ
XYZ
On embarcation day, supervisor takes Memory Stick with CAD files folder und uploads on
off-shore laptop. From there, sync to tablets.
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16
Scope of analysis
Materials are send offshore regardless of current work execution; Preparation

and packing of containers does not follow the work sequence
Synchronize containers preparation and delivery with offshore work planning
Define container content check-list according to work sequence
Coordination of
transports from
onshore to offshore
lists
@ KAEFER Maca
Communication of
delivery dates with
execution team
Materials for same deck but different cabins are mixed up at storage and in
containers which forces multiple unnecessary handlings steps
Assign
team to
activity per cabin
Pack container content
in sorted
packages
based of personal
Offshore
team
does
not
have any overview
availability
competences
and about the current material status
(delivered/upcoming materials)
experience
Define ideal work
for transparent
sequenceInstall material tracking
Execution
of activitycommunication of delivery status
materials
blocks the further work proceeding; Multiple
PrepareDisposal
work of dismantled
Clean
and organize
shifting of materials within
outside
authorization
areaand
upon
finish of the cabin before final disposal
Sharing demolition schedule
with client and alignment with client on the
Communicate
provision of empty disposal
container in advance
conclusion
Coordination of returns
of containers
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18
Logistics process
Storage and
preparation
Reception of
materials from
suppliers and
headquarter
(Contagem)
Storage of
materials
Packing of
containers
Packing containers
for further
shipment
Preparation of
packing lists per
container
Preparation of
materials for
further shipping
Shipping
Transportation of
container to
Petrobras
logistics center
Shipping of
materials
(conducted by
Petrobras)
On board
logistics
Disposal of
materials
Reception of
materials
Transportation of
removed materials
Transportation
between
containers and
cabins
Separation and
disposal of
removed materials
(per group of
rubbish)
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KWS1301_PRES_131015_2_FEB_Analysis Presentation.pptx
19
Material shortage P-32 (example)
Analysis
2 cabins
(402 & 402A)
Deck 300
3 cabins
(308A, 308B, 310)
Deck 400
Deck 500
Remaining cabins:
Overstaffing of remaining
jobs
Up to 8 persons per cabin;
Workers block each other
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20
Consequences of material shortages P-32 (examples)
Analysis
Missing steel grid
Extra work of 2 workers

for almost 2 days
Missing insulation clips
Insufficient quality
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21
Logistics process
Storage and
preparation
Reception of
materials from
suppliers and
headquarter
(Contagem)
Storage of
materials
Packing of
containers
Packing containers
for further
shipment
Preparation of
packing lists per
container
Preparation of
materials for
further shipping
Shipping
Transportation of
container to
Petrobras
logistics center
Shipping of
materials
(conducted by
Petrobras)
On board
logistics
Disposal of
materials
Reception of
materials
Transportation of
removed materials
Transportation
between
containers and
cabins
Separation and
disposal of
removed materials
(per group of
rubbish)
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22
Material storage: Arrangement of storage racks
Analysis
Current situation as of today
Potential: New rack arrangement
Floor space
Floor space
Initial rack position
Racks position
(new concept)
Lack of storage has be stated in initial

interviews
30,74 m of racks available initially
41,67 m of rack length can be realized

by re-arranging existing shelfs
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23
Materials preparation and packing of containers
Materials are stored per platform whilst

containers are packed per deck
Materials of different decks are mixed
and have to be shifted multiple timed
during packing of containers
Materials are packed per deck

(Photo: Materials delivery for deck 500)
Order of materials is not sorted per cabin
This leads to multiple handling steps on
the platform for the preparation of the
installations of each cabin
Analysis
Furniture for
Cabin 402A
Cabin 417
Cabin 506
Cabin 510
Cabin 512
Furniture for
Cabin 506
Cabin 510
Cabin 512
Cabin 520
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25
Logistics system (current vs. just-in-time principle)
Examples for understanding:
Cement
and sand
Tiles and
vinyl
Analysis
Examples for understanding:
Pipes
Furniture
Panels
Outfitting
material
8 of 11 containers on platform are for

permanent storage
A lot of additional material movement on
board is needed
Material
for
11.11.13
Material
for
15.11.13
Material
for
19.11.13
Material
for
15.11.13
Material
for
19.11.13
Workshop implementation: Containers will

be packed and shipped according to the
work planning and sequence
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26
Workshop
Demolition
Floor treatment
and laying
Approx. transport
505 kg
values
3,1 m
Pack A BLUE
Anchors
Metal grid
L-profile
(Insulation)
Drains (ralos)
Technical installations
2.130 kg
3,1 m
Pack B YELLOW
Cement
Sand
Additivo
Cables
U-profile for walls
Pipes
Wall and ceilings
Furniture and finishing
1730 kg
6,2 m
Pack C GREY
Wall panels
Ceiling panels
Profiles
Lights, switches
Diffusors
Window frames
Doors
1.335 kg
6,0 m
Pack D BLACK
Furniture
Finishing
Accessories
Reading lamps
All material is divided into groups and by cabin. The groups are assigned in a way that the material is used
within two to five days.
The packs are defined and delivered in the work sequence. Packs for different cabins can be combined in one
container but one pack is never to be split over containers.
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27
Introduction of a system for container contents according to work sequence
Workshop
Additive for
cabins
506+512+510
Pack C for
cabin 308
Concrete for
cabins
506+512+510
Pack B for
cabin 514
Sand for cabins

506+512+510
Pack A for
cabin 310
Container content per material group (line of work)

Order does not follow work execution sequence
Consequence: missing material or wrong material
stopped production offshore and deck space blocked
with containers that are half full
Different delivery packs for different cabins can be

packed in one container
Packs are not supposed top be spread over differnet
containers
Material arrives according to installation sequence
Have materials available in the right relations and quantities offshore

Introduction of delivery packs aligned with work sequence
Quicker container turnover and shorter container stays on working deck
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28
Container content (according to loaded Delivery Packs
Workshop
Container Content List (Packs)
Content of individual Packs

ITEM
MATERIAL
UNIDADE
CANTONEIRA EM AO CARBONO 1"x1"x1/8", 1,19 Kg/m GRAPA DA ANCORAGEM DA TELA TELCOM
und
ARMAO EM TELA TELCOM PARA ESTRUTURAS DE

CONCRETO ARMADO COM MALHA QUADRADA
10x10cm, DIMETRO DOS FIOS 4,2x4,2mm, SEO
1,38x1,38 - GERDAU
PAINEL RGIDO DE L DE ROCHA, COM ACABAMENTO EM

ALUMNIO REFORADO, COM DENSIDADE MNIMA DE 128
KG/M, ESPESSURA DE 25MM, PNR-128 - ROCK FIBRAS
TELA GALVANIZADA MALHA 1/2" FIO 24
PINO LISO COBREADO PARA MQUINA CAPACITIVA 1

1/2"
und
RALO PARA BANHEIRO 15X15 EM INOX, FLANGEADO
und
CANTONEIRA EM AO CARBONO 2 1/2" X 5/16" 7,44Kg/m
ARRUELA PARA PINO COBREADO
CONSUMVEIS
QUANTIDADE
m
VIDE
NECESSIDADE
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Container packing
Analysis
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Container packing
Workshop
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Packed furniture
Workshop
Furniture before shipping in Maca
Furniture in container on P-32
After a meeting with the producer changes will come asap

New packaging with stronger material, protected corners and waterproof cover
Change of bed design/construction to eliminate left/right version
Change of wardrobe door to make it useable both left and right
A pricing will be calculated to use only single wardrobes instead of singles and doubles
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32
Self-made packaging takes 45 minutes per box, partly with two people
Granite countertops with bassins
Analysis
Packed urinal
Introduction of multiuse packaging units is needed

For proper protection of repeatedly delivered items
Better protection material is needed also as a multiuse solution that stays in the
packaging units
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33
Reusable transport boxes
Multiuse boxes made for protection

Forklift handleable
Flexible in means of different sizes
Optimal protection
Workshop
Box for 3 or 4 bassin sets

With included foam protection
For multiple sizes
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34
Transport of small and medium sized items
Workshop
day 23
toilet
seat
day 12
cables
day 5-7
paint
thinner
day 18
floor
tiles
Material packed and shipped in a mixed
order without consideration of work
planning
Labeled boxes are packed with

material belonging together with
respect of the work planning
Reduction of handling steps by 75%
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35
Rack system for furniture transports
Input H. Habedank
Vision
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Logistics process
Storage and
preparation
Reception of
materials from
suppliers and
headquarter
(Contagem)
Storage of
materials
Packing of
containers
Packing containers
for further
shipment
Preparation of
packing lists per
container
Preparation of
materials for
further shipping
Shipping
Transportation of
container to
Petrobras
logistics center
Shipping of
materials
(conducted by
Petrobras)
On board
logistics
Disposal of
materials
Reception of
materials
Transportation of
removed materials
Transportation
between
containers and
cabins
Separation and
disposal of
removed materials
(per group of
rubbish)
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37
Logistics communication process (simplified)
Analysis
(1) Request
Project management
(2) Proceeding of request
and planning
Storage Maca
(Project office)
(3) Feedback
(4) Delivery of packed

containers
(within 24 hours)
Continuous arrival of
materials
Suppliers
No transparency about
next delivery contents
Timing of next deliveries
unknown
Logistics center
(5) Shipping of
container to
platform
Delivery duration
ca. 5 days
Storage
Contagem
(HQ)
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38
Structure of logistics tracking tool
Workshop
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39
Logistics process
Storage and
preparation
Reception of
materials from
suppliers and
headquarter
(Contagem)
Storage of
materials
Packing of
containers
Packing containers
for further
shipment
Preparation of
packing lists per
container
Preparation of
materials for
further shipping
Shipping
Transportation of
container to
Petrobras
logistics center
Shipping of
materials
(conducted by
Petrobras)
On board
logistics
Disposal of
materials
Reception of
materials
Transportation of
removed materials
Transportation
between
containers and
cabins
Separation and
disposal of
removed materials
(per group of
rubbish)
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40
On board logistics
Analysis
Delivery too early and not following the work sequence
Deck 100
Deck 200
Deck 300
Deck 400
Deck 500
Deck 600
Panels for
Cabin 510
Panels for
Cabin 402
Panels for
Cabin 310
1
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44
On board logistics
Analysis
Deck 100
Delivery too early and not following the work process
Transport up to deck 300 (wrong deck/cabin),

Materials of different cabins mix up and block cabins
Deck 200
2
Deck 300
Deck 400
Deck 500
Deck 600
Panels for
Cabin 510
Panels for
Cabin 402
Panels for
Cabin 310
1
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45
On board logistics
Analysis
Deck 100
Deck 200

Transport back down to deck 500 (extra transport)
Deck 300
Deck 400
Deck 500
Deck 600
3
Panels for
Cabin 510
Panels for
Cabin 402
Panels for
Cabin 310
1
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46
On board logistics
Analysis
Deck 100
Deck 200
2

Transport back down to deck 500 (extra transport)
Installation of wrong materials in wrong cabin
Deck 300
Deck 400
Deck 500
3
4
Deck 600
Panels for
Cabin 510
Panels for
Cabin 402
Panels for
Cabin 310
1
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47
Material disposal after demolition
Small pieces are thrown on a hub after demolition

Additional sorting and packing activities after
demolition (Photo: 4 workers sort material)
Analysis
Big elements are not cut in transportable parts

during demolition
Additional cutting activities become necessary
after demolition (Photo: Extra cutting activity)
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Titel
48
Removal and disposal of materials
Analysis
1
Removed material blocks
work space
Multiple handlings within
cabins to free space for
further works
2
No sufficient container
capacity available for
rubbish disposal
Removed materials are
partly stored outside
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Titel
49
Areas for improvement on the work preparation process
Work sequence, team organization and partially installation method left to

operator discretion errors, rework and lost time are the consequences
Create installation standards (e.g. installation if walls U-profile)
Attribute and demand responsibility for work organization to supervisors
availability
Define ideal work
sequence
Prepare work
authorization
Tasks given to teams without targets; focus on keeping everybody busy rather
Assignthan
team
to activity
driving
performance; some hours of work content often given for a day
based ofImplement
personal management by targets with performance tables as basis
competences and
experience
Drawings
are not always made available for operators before the start of the
Execution
of activity
activity and are not checked for quality and content in forehand
Clean and organize
Define
area upon
finishsystematic preparation routine (and time-slot) - Kamishibai
Communicate
Required materials and tools are not prepared in advance leading to start-up
conclusion
losses e.g. waiting for container to be positioned, transport materials by hand
Start preparation of following day mid-afternoon of previous day
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50
Communication onshore-offshore
We need !
!!!
Workshop
Ok!
Ok!
!!!
?
Lets do!
We
need
!
Ok!
Material request
Equipment request
Technical support
Detailed work planning

Material status tracking
Construction plans
Ok!
Lets
do !
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51
Analysis
Demolition
(1) Surface
treatment
Floor treatment
and laying
(2) Welding
of elements
(3) Painting
of floor
Technical
installations
Wall and
ceilings
Furniture and
finishing
(4) Concrete
application
Welding work are conducted before the surface

treatment has been finished
Surface treatment
Welding
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52
Analysis
Demolition
(1) Surface
treatment
Floor treatment
and laying
(2) Welding
of elements
(3) Painting
of floor
Technical
installations
Wall and
ceilings
Painted floor
(4) Concrete
application

Painting has been applied before drains have been

welded (additional painting becomes necessary)
Furniture and
finishing
Pending welding job
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53
Analysis
Demolition
(1) Surface
treatment
Floor treatment
and laying
(2) Welding
of elements
(3) Painting
of floor
Technical
installations
(4) Concrete
application

Painting has been applied before drains have been

welded (additional painting becomes necessary)
Wall and
ceilings
Furniture and
finishing
Cleaning of painted floor
Ongoing welding job
Ongoing surface
treatment
Painting is applied before surface treatment and

welding jobs have been accomplished (which causes
extra cleaning of painted floor sections)
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54
DRYING TIME
> 12
Pa i nti ng of compl ete fl oor s urfa ce (l a yer 3)
0,5
DRYING TIME
> 12
0,5
DRYING TIME
Cabin installation process
6_Insulation
7_Concrete on
Floor
> 12
Ins ta l l pi ns (wel d, gl ue)
Cut a nd i ns ta l l mi nera l wool ma ts
2,5
Pl a ce a nd fi x s teel gri d
Mi x concrete components a nd tra ns port i ns i de
2,8
Appl y concrete on the fl oor a nd di s tri bute
4,5
Workshop
DRYING TIME
Waggon
1_Demolio
2_Tratamento de
superficies
3_Externo (BR)
4_Trabalho a
quente e solda
# Op.s
Hora/
Cabine
Remove furni ture
4,0
Remove wa l l a nd roof pa nel s , profi l es a nd fl oor (vi nyl + concrete)
3,5
Remove ba throom modul e a nd ol d ducts , pi pes a nd further cei l i ng i ns ta l l a ti ons
2,0
Tra ns porta ti on of removed ma teri a l s a nd cl ea ni ng
2,0
Surfa ce trea tment (needl e ma chi ne + gri nder)
11
Cl ea ni ng (wi th brus h)
0,5
Mea s uri ng/ma rki ng of new i ns ta l l a ti ons
Openi ng of dra i n hol es (Petrobra s )
2,5
Remova l of ol d dra i ns a nd cl os i ng of ol d dra i n hol es (Petrobra s )
2,5
Wel di ng of dra i ns
Wel di ng of a nchors (on the fl oor)
Wel di ng of bi g profi l es on the fl oor (ba throom)
Cl ea ni ng (wi th brus h)
0,5
Touch up pa i nti ng of a nchors /wel di ng s pots (fl oor)
Touch up pa i nti ng of profi l es (on fl oor s i des )
0,5
Process steps
DRYING TIME
5_Pintura
DRYING TIME
DRYING TIME
6_Insulation
7_Concrete on
Floor
8_Tubulacao I
9_Eletrica I
10
11
10_HVAC I
11_Paineis
Cut, gl ue a nd i ns ta l l pi pes (hori zonta l )
Remove ol d ca bl es a nd ca bl e tra ys
2
2
Remove
Prepa
ra tifurni
on ature
nd wel di ng of s upports for HVAC ducts
4
2
4,0
2
Remove
wa l l a nd roof pa nel s , profi l es a nd fl oor (vi nyl + concrete)
Ins
ta l l ducts
4
2
3,5
2
Remove
ba throom
modul
Ins
ta l l profi
l es on fl
oor aenda nd
wa loll d ducts , pi pes a nd further cei l i ng i ns ta l l a ti ons
4
2
2,0
4
Tra ta
nslporta
onnel
of sremoved
teri aCUT
l s a nd
cl ea ni ng
Ins
l wa l ltipa
(i ncl . ALLma
FINAL
OUTS)
4
3
2,0
8,5
11_Paineis
2_Tratamento de
superficies
Surfa
treaprofi
tment
Ins
ta ce
l l roof
l es(needl e ma chi ne + gri nder)
4
8,5
Cl ea(ALL
ni ngCUT
(wiOUTS)
th brusah)
Cut
nd Ins ta l l roof pa nel s
1
3
0,5
9
Meatasluri
of new i ns ta l l a ti ons
Ins
l wing/ma
ndowrki
frang
mes
12_Eletrica II
3_Externo (BR)
13_Tubulacao II
Openi
of dra
hol
esl l (Petrobra
s ) a nd s wi tches
Run
cang
bl es
behii nnd
wa
s to s ockets
3
2
2,5
4
Remova
olidnsdra
nd cl
os i ng
Cut,
gl uel aofnd
ta lilnspiapes
(verti
ca lof
) ol d dra i n hol es (Petrobra s )
3
2
2,5
4
Weltadil lng
dra i nsfl oor ti l es (i ncl . fi l l i ng of ga ps )
Ins
baof
throom
3
2
Wel di ngTIME
of a nchors (on the fl oor)
DRYING
4
12
Wel
di ng
g profi
Fi
l l i ng
ofof
ti lbi
e joi
nts l es on the fl oor (ba throom)
1
2
4
1
Cl ea ni ngTIME
(wi th brus h)
DRYING
0,5
12
Touch
i nti(ing
nchors
ng )s pots (fl oor)
Ins
ta l lup
toipa
l ets
nclof
udiang
verti/wel
ca l pidipes
1
2
1
2
Touch
nti ng of profi l es (on fl oor s i des )
Ins
ta l lup
bapa
s s i ns
1
2
0,5
2
1,5
Pa i ta
ntil lngs hower
of compl
ete
oor sdiurfa
ce (l acayer
Ins
ca bi
n (iflncul
ng verti
l pi1)pes )
1,5
4
> 12
DRYING
TIME hooks , ha ndel s , etc.
Ins
ta l l towel
>0,5
12
Pa i ta
ntil lnghea
of ticompl
ete flraoor
Ins
ng towel
ck s urfa ce (l a yer 2)
0,5
DRYING
Appl
y s i lTIME
i con on fl oor a nd i ns ta l l a ti ons (i .e. toi l et)
> 112
0,5
Pa i ta
ntil lngbaofthroom
compl door
ete fl oor s urfa ce (l a yer 3)
Ins
0,5
1,5
> 12
DRYING
Ins
ta l l sTIME
ockets a nd s wi tches
> 12
1,25
Pa i ta
ntil lngl i ghts
of compl ete fl oor s urfa ce (l a yer 4)
Ins
0,5
1,5
DRYING
Ins
ta l l sTIME
pea kers
> 12
0,25
pire
nsdetectors
(wel d, gl ue)
Ins ta l l fi
(Petrobra s )
2
0,25
Cutta
a nd
taor
l l mi nera l wool ma ts
Ins
l l dii ns
ffus
2,5
0,25
Pl a cey aflnd
x s teelagri
Appl
oorfiunderl
yerd (2*), gri nd a nd cl ea n
1
4
Mi x concrete
DRYING
TIME components a nd tra ns port i ns i de
2,8
12
concrete
on the fl oor a nd di s tri bute
Appl y vi
nyl fl oor
4,5
5
DRYING
Ins
ta l l caTIME
bi n wi ndow curta i ns
72
1
Prepa
ndets
wel di ng s upports for pi pes
Ins
ta lre
l claos
2
3
2
5
2
3
2
10
0,5
0,5
Ins ta l l pi ns (wel d, gl ue)
Cut a nd i ns ta l l mi nera l wool ma ts
2,5
Pl a ce a nd fi x s teel gri d
Mi x concrete components a nd tra ns port i ns i de
2,8
Appl y concrete on the fl oor a nd di s tri bute
4,5
9_Eletrica I
Waggon
10
10_HVAC I
1_Demolio
12
3
13
14
4_Trabalho a
quente e solda
14_Banheiro
5_Pintura
15
15_Eletrica III
6
16
6_Insulation
16_HVAC II
17
7
17_Finish
Floor
7_Concrete
on
Floor
72
Ins ta l l new ca bl e tra ys (i ncl . s upports )
Cut, gl ue a nd i ns ta l l pi pes (hori zonta l )
Remove ol d ca bl es a nd ca bl e tra ys
Ins ta l l new ca bl e tra ys (i ncl . s upports )
Pul l new ca bl es
Prepa ra ti on a nd wel di ng of s upports for HVAC ducts
Ins ta l l ducts
Ins ta l l profi l es on fl oor a nd wa l l
Ins ta l l wa l l pa nel s (i ncl . ALL FINAL CUT OUTS)
8,5
Ins ta l l roof profi l es
8,5
Cut (ALL CUT OUTS) a nd Ins ta l l roof pa nel s
Cut (ALL CUT OUTS) a nd Ins ta l l roof pa nel s
Ins ta l l wi ndow fra mes
Ins ta l l wi ndow fra mes
8
18
8_Tubulacao I
Cut,
a nd(iincl
ns ta
l l ng
pi pes
Ins tagll lue
beds
udi
curta(hori
i ns )zonta l )
18_Mobiliario e
acabamentos finais Ins
Remove
espos
a ndi tica
e tra
ta l l taolbldescaablnd
onblcha
i rsys
9_Eletrica I
19
10
11
12
19_Eletrica IV
10_HVAC I
11_Paineis
12_Eletrica II
2
# Op.s
Process steps
Prepa re a nd wel di ng s upports for pi pes
KWS1301_PRES_131025_1_PEL_Presentation
Brazil.pptx
12 12_Eletrica II
Run ca bl es behi nd wa l l s to s ockets a nd
s wi tches
Pul l new ca bl es
> 12
DRYING TIME
72
Prepa re a nd wel di ng s upports for pi pes
Hora/
4
Cabine
5
> 12
DRYING TIME
8_Tubulacao I
2
3
2
2,5
new
bl e tra ys (i ncl . s upports )
Ins ta l l ca
bi ncadoor
2
3
4
1,5
Puleal new
Cl
ni ng ca bl es
2
3
5
0,5
Prepa
ti onl iaghts
nd wel di ng of s upports for HVAC ducts
Ins
ta lra
l bed
Ins ta l l ducts
2
2
2
1
2
Ins ta l l profi l es on fl oor a nd wa l l
Ins ta l l wa l l pa nel s (i ncl . ALL FINAL CUT OUTS)
8,5
Ins ta l l roof profi l es
8,5
Run ca bl es behi nd wa l l s to s ockets a nd s wi tches
LEAN MARITIME
3
55
Daily control of work execution status and next steps
Workshop
25.10.2013
15.11.2013
LEAN MARITIME
56
Workshop
Planning control board

CABINS
Cam. 308A
Cam. 308B
Cam. 310
WORK PLAN
STATUS
General plan
Progress
CRONOGRAMA E HISTOGRAMA MACROS - CENRIO DE TRABALHO DA REUNIO DE 31-10-13 - REVISO 10

LOCAL
DECK BELOW / INTERFERENCE
PISO 100
NOVO CAM 101

NOVO CAM 102
NOVO CAM 103
NOVO CORREDOR
BANHEIRO E CAM 206

BANHEIRO E CAM 221
BANHEIRO E CAM 202
BANHEIRO E CAM 210
BANHEIRO E CAM 207
BANHEIRO E CAM 204 (NO EXISTE AS ABERTA)
BANHEIRO E CAM 214
BANHEIRO E CAM 211
BANHEIRO E CAM 213
CORREDOR (NO EXISTE AS ABERTA)
SET/13
4SEM
1SEM
OUTUBRO/13
2SEM
3SEM
4SEM
1SEM
100
NOVEMBRO/13
2SEM
3SEM
4
4SEM
1SEM
DEZEMBRO/13
2SEM
3SEM
4
4SEM
1SEM
JANEIRO/14
2SEM
3SEM
4SEM
1SEM
FEVEREIRO/14
2SEM
3SEM
4SEM
4
4
- NOVA LINHA TUBULAO

PISOS 600,500,400,300,200,100
PIPES
316
305
304
308A/B
307
306
312
315
303
323
NA
3
3
3
3
3
3
3
2
3
3
3
2
2
3
3
200
2
3
4
3
4
3
3
2
4
3
3
4
3
NMERO DE VAGAS PERDIDAS

DURANTE AS OBRAS DE CIVIL DA KAEFER
0
0
0
0
0
0
0
4
6
6
10
4
3
3
3
4
3
2
2
4
3
3
2
3
4
6
3
4
3
Waggon
Ban. Cuc. 400
Cam. 402A
Ban. Col. 402
402 + BANH. COL.

ENFERMARIA
ENFERMARIA
DOTEC + SALA INSPEO
DOTEC
SAFETY OFFICE
CINEMA + PLC
CINEMA
COZINHA
COZINHA + REFEITRIO
COZINHA
RECEPO + SALA BRIEFING
REFEITRIO
REFEITRIO
CAM E NOVO BANHEIRO 402A

NOVO BANHEIRO COLETIVO (ANTIGO CAM. 402B)
BANHEIRO DA COZINHA 400
ENFERMARIA
DOTEC - NOVO CAMAROTE - AS 72
SAFETY OFFICE
SALA DO PLC
CINEMA
RECEPO
SALA DE BRIEFING
COZINHA/CMARA FRIGORFICA (NO EXISTE AS ABERTA)
REFEITRIO (NO EXISTE AS ABERTA)
3
3
3
3
3
3
2
3
3
3
3
2
2
3
3
300
4
4
4
4
4
4
3
3
3
X
2
3
3
X
2
2
2
X
2
2
3
3
3
3
3
3
3
3
2
2
3
3
3
2
2
3
3
3
3
3
3
3
3
2
3
3
3
3
3
2
3
3
3
3
4
2
2
2
2
4
3
4
3
3
3
2_Tratamento de
superficies
3_Externo (BR)
4_Trabalho a
quente e solda
3
12
8
8
6
6
4
4
10
10
6
6
4
4
6
1_Demolio
5_Tubulacao
6_Insulation
7_Pintura
8_Concrete on
Floor
6
6
2
X
400
X
X
X
X
X
X
4
X
X
4
3
4
3
3
4
3
3
4
3
3
3
5
3
5
3
5
3
5
4
4
5
4
4
Hora/
Cabine
9_Eletrica I
10
10_HVAC I
11
11_Paineis
12
12_Eletrica II
512
506
520
510
402 402A 400

banh.
banh.
Col.
Cuc.
310
308 A 308 B
6
1,5
2,5
1_Remo o de dutos
0,5
1_Remo o de tubul a o
0,5
1_Tra ns porte de entul ho
1_Li mpeza
0,5
2_Tra ta mento de s uperfi ci e
1
1
1
1
2_Li mpeza
0,5
2_Ma rca o e medi o do novo a mbi ente
2,5
next
next
next
next
3,5
next
next
next
3_Abertura dos ra l os e furos de tbul a o

3_Remo o dos ra l os a nti gos & Fecha mento dos a nti gos
furos
4_Sol da dos Ra l os
3
3
4_Sol da de gra pa (0,5h/m)
4_Sol da de ba rra de conten o
4_Li mpeza
0,5
1
1
1
5_Sol da gem de s uportes de tubul a o
5_Prepa ra o de tubos
next
next
next
6_Pi na gem
6_Corte e i ns ta l a o de l de rocha
2,5
next
next
6_Ins ta l a o de tel a
7_Pi ntura de Gra pa
next
7_Pi ntura de ba rra de conten o
0,5
next
next
7_Pi ntura do pi s o 1 dem o
8_Col oca o da a rma o Tel com
1,5
> 12
0,5
> 12
0,5
> 12
0,5
1
1
1
1
1
1
1
next
next
next
next
3,5
4,5
next
next
next
next
8_Apl i ca o da na ta de a ca ba mento
72
next
next
next
9_Ins ta l a o da s el etroca l ha s
next
next
9_Ins ta l a o de novos ca bos
12
next
next
next
next
next
next
10_Sol da gem dos s uportes de HVAC
1,5
10_Ins ta l a o de dutos
1,5
11_Ins ta l a o de perfi s
11_Ins ta l a o de pa i nei s
1
1
1
1
1
11_Ins ta l a o de perfi s de teto
11_Prepa ra o e Ins ta l a o de pa i nei s de teto
next
next
8_Mi s tura do concreto e tra ns porte
> 12
8_Apl i ca o do concreto
11_Ins
ta l a
de a ca ba mentos de es coti l ha s
Ser substituido somente
o piso
dao cozinha.
CABINE STATUS
514
3
3
2
1_Remo o de pi s o
1_Remo o do modul o ba nhei ro
9_Remo o de ca bos a nti gos e el etroca l ha s
X
X
X
X
# Op.s
1_Remo o de pa i nei s
1_Remo o de perfi s
2_Pos i ci ona mento dos ra l os
CAM E NOVO BANHEIRO 310

CAM E NOVO BANHEIRO 308A
CAM E NOVO BANHEIRO 308B
BANHEIRO E CAM 305
BANHEIRO E CAM 304
BANHEIRO E CAM 307
BANHEIRO E CAM 316
CAM E NOVO BANHEIRO 306
CAM E BANHEIRO 323
BANHEIRO E CAM 315
BANHEIRO E CAM 312
BANHEIRO E CAM 303
BANHEIRO E CAM 313
Work Steps
OBSERVAES
1_Remo o de mobi l i a ri os
next
1
1
next
12_Correr ca bos na s pa redes pa ra i nterruptores e toma ds
13_Ins ta l a o de cera mi ca s
next
13_Ins ta l a o de va s os
next
next
12
CAM E BANHEIRO 514

CAM E BANHEIRO 512
CAM E BANHEIRO 506
CAM E BANHEIRO 520
CAM E BANHEIRO 510
BANHEIRO COLETIVO 500
500
4
4
4
4
4
4
4
4
4
4
3
3
3
3
3
2
3
2
3
3
2
2
2
2
10
10
3
4
6
2
2
2
3
CORREDOR 600 (NO EXISTE AS ABERTA)

CAMARA FRIGORFICA (NO EXISTE AS ABERTA)
VESTIRIO / BANHEIRO COLETIVO (NO EXISTE AS ABERTA)
LAVANDERIA (NO EXISTE AS ABERTA)
3
600
HISTOGRAMA (PESSOAS POR SEMANA)

FRENTES DE TRABALHO / CAMAROTES POR SEMANA
38
38
35
13
5
4
4
4
4
32
31
31
33
32
31
34
35
49
55
52
46
41
34
24
16
10
14
13
13
12
12
13
11
14
15
14
13
Cam. 506
Cam. 512
Cam. 514
Efetivo trabalhando nas frentes liberadas

Efetivo dedicado para trabalhos de Tubulao
Local do compartimento inferior que ser interditado durante as atividades do compartimento superior (esgoto).
No existem AS's abertas;
Problems /
Countermeasures
Cam. 510
Cam. 520
Stickers
1.
2.
3.
A4
13_Ins ta l a o da s pi a s
13_Ins ta l a o de boxes de ba nho
13_Ins ta l a o de a ces s ori os
14
14_Eletrica III
15
15_HVAC II
16
16_Finish Floor
186
13_Ins ta l a o dos s uportes a queci dos pa ra toa l ha s
13_Ins ta l a o da porta do ba nhei ro
3
3
5
1
1
1,5
14_Ins ta l a o de toma da s , i nterruptores
1,25
14_Ins ta l a o de l a mpa da s
1,5
next
next
14_Ins ta l a o de l umi n ri a s da s ca ma s
14_Ins ta l a o de a uto-fa l a ntes (BR)
0,5
14_Ins ta l a o de s ens ores (BR)
0,5
15_Ins ta l a o de di fus ores
0,25
next
16_Apl i ca o da na ta de a ca ba mento
16_Apl i ca o de pi s o vi ni l i co
17_Ins ta l a o de corti na s
6,25
17_Ins ta l a o de a rma ri os
17
13_Banheiro
17_Ins ta l a o de bel i ches

17_Mobiliario e
acabamentos finais 17_Ins ta l a o de es cri va ni nha
17_Ins ta l a o de porta s
17_Li mpeza
10
2,5
1,5
Unforced errors /
Claims
1.
2.
3.
A4
LEAN MARITIME
KWS1301_PRES_131111_1_STO_Planning control board.pptx
Workshop

Week planning
Work process
1_Demolio
Monday
Hours Hours
Cabin MAT Person
Cabin
(Plan) (Real)
510
Tuesday
Hours Hours
MAT Person
Cabin
(Plan) (Real)
Wednesday
Hours Hours
MAT Person
Cabin
(Plan) (Real)
Thursday
Hours Hours
MAT Person
Cabin
(Plan) (Real)
Friday
Hours Hours
MAT Person
Cabin
(Plan) (Real)
Saturday
Sunday
Hours Hours
MAT Person
Cabin
(Plan) (Real)
MAT Person
Hours Hours
(Plan) (Real)
2_Tratamento de superficies
3_Externo
4_Trabalho a quente e solda
5_Pintura
6_Insulation
7_Concrete on Floor
8_Tubulacao
9_Eletrica I
10_HVAC I
11_Paineis
12_Eletrica II
13_Tubulacao II
14_Banheiro
15_Eletrica III
16_HVAC I
17_Finish Floor
18_Mobiliario e acabamentos finais
19_Eletrica IV
LEAN MARITIME
58
Workshop

Week planning
Work process
1_Demolio
Monday
Hours Hours
Cabin MAT Person
Cabin
(Plan) (Real)
510
Tuesday
Hours Hours
MAT Person
Cabin
(Plan) (Real)
Wednesday
Hours Hours
MAT Person
Cabin
(Plan) (Real)
Thursday
Friday
Hours Hours
MAT Person
Cabin
(Plan) (Real)
Saturday
Hours Hours
MAT Person
Cabin
(Plan) (Real)
Sunday
Hours Hours
MAT Person
Cabin
(Plan) (Real)
MAT Person
Hours Hours
(Plan) (Real)
3_Externo
5_Pintura
6_Insulation
7_Concrete on Floor
Monday
8_Tubulacao
9_Eletrica I
10_HVAC I
11_Paineis
Work process
Cabin MAT Person
12_Eletrica II
13_Tubulacao II
14_Banheiro
1_Demolio
15_Eletrica III
16_HVAC I
17_Finish Floor
18_Mobiliario e acabamentos finais
19_Eletrica IV
510
Tuesday
Hours Hours
Cabin
(Plan) (Real)
MAT Person
Hours H
(Plan)
3_Externo
5_Pintura
6_Insulation
LEAN MARITIME
59
Workshop
LEAN MARITIME
Scope of analysis
Work assignment for the teams is short-sighted and does not conclude the
whole day
Supervisors check progress each afternoon and set work assignments for
the following day including staffing based on workload not on availability
Material planning and manning differ Men are available but material is not
Prepare 10-day-forward for all activities and order material accordingly
based of personal
competences and
experience
Clean and organize
area upon finish
Communicate
conclusion
Processes run out of sequence and leads to repeating wasted hours and
material
Keep the work steps in the appropriate sequence to avoid unnecessary work
Material has been delivered to the platform but cannot be found
Implement material tracking and control to maintain a clear overview over
material location an movement
Needed machinery/tools are not available for every member of the team
Define tool setup and provide the full set accordingly to every member
Old-fashioned and partly inappropriate work techniques are used
Define the techniques to be used, re-evaluate frequently and adjust if needed
LEAN MARITIME
61
Work execution
Analysis
No sequence of work steps could be observed

Steps are skipped and require more work and
subsequent re-doing of preceding steps
No current status is known due to ongoing
repetition, this leads to addtl. waiting time
Logistics also have to follow the process
sequence to avoid cluttering of spaces
Team size is not adjusted to workload but

availability
Subsequently overstaffing slows work down,
people blocking each other
Set teams according to needed
competences so that every step can be
conducted by an appropriate specialist
Execution
Not enough tools available for each member of trade

Improper tools and equipment have been seen,
leading to long process times
No structured work space preparation, a lot of
unnecessary movements can be seen
Setup of workplace in the morning takes up to 1h
Not all needed material is available

Storage on platform is not organized
Improvisation in material usage faulty uses
materials needed for other jobs and further
improvisation: each leading to waiting and
execution times on the platform
Unavailability of material halts process
LEAN MARITIME
63
Execution process
Demolition
Removal of
Furniture (beds,
tables, closets,
curtains)
Electrical
devices (lights,
sockets,
switches)
Vinyl floor and
concrete
Wall panels and
ceiling
Floor treatment
and laying
Surface treatment
Welding
For floor
installation
(anchors, grids)
For bathroom
installation
(profiles,
drains)
Painting of floor
(4 layers)
Concrete
application
Technical
installations
Electricity
installations:
Supports
Cables
Devices
(lights,
sockets,
switches)
HVAC installations:
Supports
Ducts
Diffusors
Piping
installations:
Supports
Pipes
Wall and
ceilings
Insulation
Pins
Mineral wool
boards
Clips and mesh
wire
Profile installations
Floor
Wall
Ceiling
Furniture and
finishing
Installation of
furniture (beds,
tables, closets,
curtains)
Finish of electrical
and HVAC
installation
Panels installation
Floor
Wall
Ceiling
LEAN MARITIME
64
Execution process
Demolition
Removal of
Furniture (beds,
tables, closets,
curtains)
Electrical
devices (lights,
sockets,
switches)
Vinyl floor and
concrete
Wall panels and
ceiling
Floor treatment
and laying
Surface treatment
Welding
For floor
installation
(anchors, grids)
For bathroom
installation
(profiles,
drains)
Painting of floor
(4 layers)
Concrete
application
Technical
installations
Electricity
installations:
Supports
Cables
Devices
(lights,
sockets,
switches)
HVAC installations:
Supports
Ducts
Diffusors
Piping
installations:
Supports
Pipes
Wall and
ceilings
Insulation
Pins
Mineral wool
boards
Clips and mesh
wire
Floor
Wall
Ceiling
Furniture and
finishing
Installation of
furniture (beds,
tables, closets,
curtains)
and HVAC
installation
Panels installation
Floor
Wall
Ceiling
LEAN MARITIME
65
Removal of concrete floor
Analysis
Work sequence
Current work process equals

Ping Pong principle
1st operator removes the floor
with air hammer, 2nd worker
waits (and vice versa)
Worker Worker
1
2
Productive time
Waiting time
Observation on P32, Cabin 402 A, 10.10.2012
Worker 1 removes floor with

crowbar/air hammer,
Worker 2 follows and packs
removed concrete in disposal bag
(or boxes) and cleans up
LEAN MARITIME
66
Wrong air hammer attachment
Workshop
Usage of wrong
attachment for tool with
only low impact on the
concrete floor
Usage of brought
attachment for extended
impact to remove
concrete
LEAN MARITIME
Titel
67
Execution process
Demolition
Removal of
Furniture (beds,
tables, closets,
curtains)
Electrical
devices (lights,
sockets,
switches)
Vinyl floor and
concrete
Wall panels and
ceiling
Floor treatment
and laying
Surface treatment
Welding
For floor
installation
(anchors, grids)
For bathroom
installation
(profiles,
drains)
Painting of floor
(4 layers)
Concrete
application
Technical
installations
Electricity
installations:
Supports
Cables
Devices
(lights,
sockets,
switches)
HVAC installations:
Supports
Ducts
Diffusors
Piping
installations:
Supports
Pipes
Wall and
ceilings
Insulation
Pins
Mineral wool
boards
Clips and mesh
wire
Floor
Wall
Ceiling
Furniture and
finishing
Installation of
furniture (beds,
tables, closets,
curtains)
and HVAC
installation
Panels installation
Floor
Wall
Ceiling
LEAN MARITIME
68
Surface treatment technique
Analysis
LEAN MARITIME
69
Surface treatment
In min/m
Workshop
-83%
120
Tested
20
To be tested
Tested
Old
New
surface surface
treatment treatment
Advanced
technologies known
in ship building /
maintenance
Investment costs
Ca. 5000-7500
(2 proposal received)
LEAN MARITIME
70
Selfmade template to accelerate work preparation (markings)
Workshop
Platzhalter Bild
Anchor allocation varies and forces lots of manual

labor (adjustment of grid to anchors)
Distance between anchors is too big: addtl. fixing
points welded directly onto the ground
Additional manual labor to adjust grid to
anchors for welding and add further points
No system is recognizable
A team of two works on this job for 3 hours
Set anchor distance according to grid measures

Built a template to easy markings and avoid further
measurements as long as the grid size remains as is
The production of a template out of thin
metal helps to mark anchor positions
Position marking spots in the template
Move it over the ground and allocate positions
LEAN MARITIME
71
Mesh grid installation on floor
Workshop
28
62
20
14
TOTAL
24
(39%)
Preparation
(mesh grid,
tools)
Fix mesh grid
Cleaning,
Touch up
28
10
38
TOTAL
Preparation
(mesh grid,
tools)
Fix mesh grid
0
Cleaning,
Touch up
Current contract requires welding of steel grid;

Usage of wire has to confirmed by client
LEAN MARITIME
72
Team constitution (initial situation)
Analysis
LEAN MARITIME
73
Activity analysis
Analysis
LEAN MARITIME
74
Activity analysis
Pilot test
LEAN MARITIME
75
Welding of anchors (for cementing) on previously painted floor
Analysis
Duration: approx.. 2 Hours*
Duration: approx.. 2 Hours*
Duration: approx.. 1 Hour*
Grinding place for anchors on

finish painted floor, followed by
extra cleaning - Waste
Weld anchors
Brush welded anchors in

preparation for painting;
Paint anchors
* Time for average cabin size of approx. 16 m
LEAN MARITIME
76
Preparation of concrete
Heavy manual labor

3 People
Mixing cement, sand and water manually
with shovels in large tray
Workshop
Usage of industry standard tools

2 People
Put components in drum, let it mix
Empty in tray & mix again immediately
LEAN MARITIME
77
Preparation of tile glue
Bad mixture and manual labor

The components do not mix well
Lower quality of mixture
Manual labor to mix
Workshop
Usage of industry standard tools

Easy to apply tool for use with drill
Mixes components well and evenly
Electric tool and faster result
LEAN MARITIME
78
Execution process
Demolition
Removal of
Furniture (beds,
tables, closets,
curtains)
Electrical
devices (lights,
sockets,
switches)
Vinyl floor and
concrete
Wall panels and
ceiling
Workshop
Floor treatment
and laying
Surface treatment
Welding
For floor
installation
(anchors, grids)
For bathroom
installation
(profiles,
drains)
Painting of floor
(4 layers)
Concrete
application
Technical
installations
Electricity
installations:
Supports
Cables
Devices
(lights,
sockets,
switches)
HVAC installations:
Supports
Ducts
Diffusors
Piping
installations:
Supports
Pipes
Wall and
ceilings
Insulation
Pins
Mineral wool
boards
Clips and mesh
wire
Floor
Wall
Ceiling
Furniture and
finishing
Installation of
furniture (beds,
tables, closets,
curtains)
and HVAC
installation
Panels installation
Floor
Wall
Ceiling
LEAN MARITIME
79
Wall cut outs for socket and switches
Analysis
40% to 60% of the cut out for electricity have to be squared

100% of all cut outs are made with round saw after the panel installation
Test of squared cut out with

jig saw
Research for round sockets
and switches (allowed to be
installed according to
contract)
LEAN MARITIME
80
Installation of light supports
Workshop
-79%
24
Wrong work sequence:

Roof panels are installed before light
supports (25 min per light)
Initial
New
installation installation
process
process
Revised work sequence:

Supports are installed before
the panels are installed
LEAN MARITIME
81
Initial prefabrication of light supports (offshore)
Analysis
Spontaneous prefabrication on board:
Light supports have been fabricated offshore by at least 2 persons

Material leftovers are used to build light supports
LEAN MARITIME
82
New prefabrication process of light supports (onshore)
Workshop
New prefabrication process (onshore at workshop)
Reduction from min 2 person to 1 person (=50% time reduction)

Production of equal, standardized parts
LEAN MARITIME
83
Initial preparation of lights
Analysis
Initial activities:
1.
2.
Lights are delivered

unprepared offshore
Lights have to be prepared
(cables and starter) during the
installation process;
min. 1 person is currently
waiting during light preparation
(of up to 25min per light)
LEAN MARITIME
84
New light preparation process
Workshop
Packed in former delivery boxes

Sent offshore ready-to-install
New preparation process
Preparation of light by 1 electrician (onshore);

Elimination of waiting time of installation team
Preparation of light is now done in 5 min
80% reduction of installation time
LEAN MARITIME
85
Misfit of cabin lights and cabin ceiling panels
Analysis
Cabin lights and ceiling panels do not fit

Hook-in mechanism of ceiling lights: 25 mm, Thickness of ceiling panels: 40mm
Rework on the ceiling panel after installation of all ceiling panels has be done
25mm
40mm
Supplier for ceiling lights does not respect the specifications
LEAN MARITIME
86
Pipe installation
Workshop
Tool boxes with separations with a set

of bends and valves of different sizes
(maintained by storage responsible)
1
Bends
Valves
Transport box
1 and are delivered whilst

valves are needed
Valves and bends are

packed in a cabin corner
Materials are completely
mixed up and do not allow
any transparancy
Examples:
LEAN MARITIME
87
Drain cut outs
Analysis
Drain cut outs have been made for the first 5 cabins bathrooms (not part of the contract)
Total time spend of approx. 10 man days (2 workers spent 1 day per cabin)
Equals costs of approx. 7.500 R$** which have to be claimed
=Drain position
On P-32 drain holes have to be cut by responsible subcontractor IESA !!

For future contracts this competence should be part of KAEFERs contract scope
*IESA = Petrobras assigned subcontractor for steelworks; **2 workers * 1 day * 5 cabins * 11 hours/shift * 68 R$/hour = 7.480 R$
LEAN MARITIME
88
Method and tooling problems example drain hole
Workshop
LEAN MARITIME
Drain installation in showers
Initial situation:
Engineering decided to install 2 drains per cabin

shower due to balancing of the platform
Waste of material (ca. 300) and time (ca. 1h x 3
persons)
Workshop
Solution:
Install only 1 drain per shower
LEAN MARITIME
90
Drain installation
Self-designed drains appear too massive

Price/piece : ca. 300
Workshop
Import of standard drains from EU / US

First price requests done during workshop
Non-welded drains
Ca. 240
(excl. import tax)
Input H. Habedank
Welded drains
Ca. 50 110
(excl. import tax)
LEAN MARITIME
91
Cabin standardization
Vision
Initial situation:
All cabin bathroom differs from each
other in terms of size and layout
Status:
Client has been informed about
benefits of standardization
Availability and conditions in Brazil to
be checked
Initial situation:
Different bed types for left and right side of the cabin
Closets vary in height and direction (left, right) as well
Pictures bathroom modules: H. Habedank

Status:
Supplier for furniture will standardize beds
(no distinction left or right any more)
Further standardization of closets to be done
LEAN MARITIME
92
HVAC ducts
HVAC ducts manually are prefabricated offshore

Poor quality and outer appearance
Analysis
Multiple suppliers for standard HVAC duct exist

Request (RFQ) at local suppliers has to be done for
make-or-buy decision
LEAN MARITIME
93
Execution process
Demolition
Removal of
Furniture (beds,
tables, closets,
curtains)
Electrical
devices (lights,
sockets,
switches)
Vinyl floor and
concrete
Wall panels and
ceiling
Floor treatment
and laying
Surface treatment
Welding
For floor
installation
(anchors, grids)
For bathroom
installation
(profiles,
drains)
Painting of floor
(4 layers)
Concrete
application
Technical
installations
Electricity
installations:
Supports
Cables
Devices
(lights,
sockets,
switches)
HVAC installations:
Supports
Ducts
Diffusors
Piping
installations:
Supports
Pipes
Wall and
ceilings
Insulation
Pins
Mineral wool
boards
Clips and mesh
wire
Floor
Wall
Ceiling
Furniture and
finishing
Installation of
furniture (beds,
tables, closets,
curtains)
and HVAC
installation
Panels installation
Floor
Wall
Ceiling
LEAN MARITIME
94
Insulation pin installation
Analysis
No best practice of pin installations (adhesive pins and pin

shooting is used)
Usage of adhesive pins does not meet safety requirement
Pin shooting is partly used

This techniques is supposed to be applied in general
Offshore work force has to be continiously briefed in using the
correct material and tools
LEAN MARITIME
Titel
95
Unprofessionell work execution with wrong tooling
Workshop
LEAN MARITIME
Installation above defined specification
Workshop
Metal mesh not required when

insulation has aluminum
reinforcement.
Contract information Anne Meyer

LEAN MARITIME
97
Overprocessing of insulation fixation
Workshop
LEAN MARITIME
Titel
98
Profile Installation: Overprocessing
Analysis
100% waste
45 cut
of corner
profiles
45
Eliminate
additional drilling
and pop rivet
fixation
LEAN MARITIME
99
Template for panel cut outs for diffusors and speakers
Screw holes
Wall
panels
Ceiling
profile
Workshop
1 cm
1 cm
From the
left
From the
right
LEAN MARITIME
100
Possible adjustments to the process of ceiling profile fixing
Current process
2 People
One person drilling, other person screwing
Self-drilling pan head screw: WRTH
Workshop
Use of self-drilling screws

1 Person due to elimination of drilling
Reduce movement
Just screwing, no changing of tools
LEAN MARITIME
101
Wall panel length
Analysis
All panels are shortened before installation

Wall panels
Wasted
material
Cutting of wall panels
Correct
length
Panels can be sourced and delivered in lengths ready-to-install
Correct
length
Savings of material
Savings of installation /cutting time
Savings of space (transport/storage)
LEAN MARITIME
102
Installation of ceiling panels

In minutes/panel
14 24 min
Analysis
4 min
5 min
5 - 15 min
5 min
9 min
12 min
Total
Fitting*
Measuring
Cutting
12 min
15 min
*Fitting (incl. Micro logistics)
LEAN MARITIME
103
Installation of ceiling panels

In minutes/panel
Workshop
4 min
5 min
10 13 min
1 -3 min
Total
Fitting*
Measuring
*Fitting (incl. Micro logistics)

Cutting
LEAN MARITIME
104
Workshop
Introduce rotating saws like Makita 5143R
Special saw discs for sandwich panels
With those
With those special sawing discs we can cut the cutting

time in half
Buy the discs for the right use (cutting of
sandwichpanels)
Use 355 mm diameter blades
E.g. Makita 5143R with 355 mm blade diameter
LEAN MARITIME
105
Template for panel cut outs for diffusors and speakers
Panel cut
outs for diffuser and speaker
have been made after the
installation of the ceiling panels
Workshop
(1) Creation of template with on board team to reduce measurement time
(2) Installation sequence to be changed; cut outs have to be made

BEFORE ceiling panels are installed
LEAN MARITIME
106
Speeding up the execution of work steps by eliminating waiting and transportation time
Workshop
LEAN MARITIME
107
Ceiling installation
Analysis
Steel structure
Supports
Ceiling panels
LEAN MARITIME
108
Workshop
Steel structure
Supports
Ceiling panels
Usage of laser
measurement tools
to conduct a exact
measurement
Training of board
team in usage of
equipment
LEAN MARITIME
109
Analysis
Steel structure
Supports
Ceiling panels
LEAN MARITIME
110
Analysis
Steel structure
Supports
Ceiling panels
LEAN MARITIME
111
Alternative ceiling supporting
Threaded rods installed at ceiling plate
Workshop
Clips for the fixation of the

ceiling profile
LEAN MARITIME
112
Low panel quality
Workshop
Height differences of >3mm
The panel quality is very low - leading to

additional work to assure quality
Removal of pop-rivets to reduce gaps in ceiling
Quality checks take up to 10 man minutes/panel
Improvement on route
Introduction of tool to control panel quality
Quality issues have been addressed in
meeting with supplier Danika
LEAN MARITIME
113
Low quality of material supplies
Analysis
LEAN MARITIME
114
Door installation
Analysis
(1) Work manual

as guidance for installation on board
Door
Manual
texttexttexttexttexttexttexttextte
xttexttexttexttexttextttexttexttex
ttexttexttexttexttexttexttexttextt
exttexttextexttexttext
(2) Training of team (supervisors and workers)

on installation technique
Door frames are drilled multiple times

Installation with 3 workers overstaffed
Door frames are

cut multiple times
LEAN MARITIME
115
LEAN News (extract)
Workshop
To be continued
LEAN MARITIME
116
LEAN News for on board work force
Workshop
LEAN MARITIME
LEAN MARITIME
www.lean-maritime.com
Stefan Opre
opree@lean-maritime.com
Pedro Leao
leao@lean-maritime.com
LEAN MARITIME

Lean Maritime

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Lean Management at KAEFER

Pilot Project: Brazil

This document is confidential and is intended

Initial situation and objectives

The refurbishment of the accommodation block

Identify and quantify waste in all areas of the

The project management and execution teams

Develop and test improvement ideas, quantify

A broaden spectrum of activities from metal

Define and deploy improved planning and work

Assign team to activity

Areas for improvement on the engineering process

Dimensions missing on drawings; Drawings printed out of scale;

delivery dates with

Complete Roombook with as-built

Common problems on drawings

Some dimensions systematically missing (e.g. position of lights,

INTERNAL CONTROL BOARD

Introduzir eixo da baine e colocar cota de

posicao da contrapara em relacao aos eixos ou a barra de contecao

Is the print correct? Size + view

Posicao do altofalante e HVAC difusor

posicao dos interruptores, tomadas (contrapara) - cotacao em relacao a antepara

Language adapted to project

Inteoduzir posicao do mobiliario que naoDocument

Information quality in isometrics

A new tool was introduced to calculate the length of

The real position of the wet unit

1. Dimension position of wet unit to

Kick-off visit on board

Check list for room content

Materials are send offshore regardless of current work execution; Preparation

Material shortage P-32 (example)

Consequences of material shortages P-32 (examples)

Missing steel grid

Extra work of 2 workers

Missing insulation clips

Material storage: Arrangement of storage racks

Current situation as of today

Potential: New rack arrangement

Initial rack position

Lack of storage has be stated in initial

41,67 m of rack length can be realized

Materials preparation and packing of containers

Materials are stored per platform whilst

Materials are packed per deck

Logistics system (current vs. just-in-time principle)

Examples for understanding:

Examples for understanding:

8 of 11 containers on platform are for

Workshop implementation: Containers will

Wall and ceilings

Furniture and finishing

Introduction of a system for container contents according to work sequence

Sand for cabins

Container content per material group (line of work)

Different delivery packs for different cabins can be

Have materials available in the right relations and quantities offshore

Container content (according to loaded Delivery Packs

Container Content List (Packs)

Content of individual Packs

CANTONEIRA EM AO CARBONO 1"x1"x1/8", 1,19 Kg/m GRAPA DA ANCORAGEM DA TELA TELCOM

ARMAO EM TELA TELCOM PARA ESTRUTURAS DE

PAINEL RGIDO DE L DE ROCHA, COM ACABAMENTO EM