Ship operators can save an average of 50% to 80%

Six Sigma is a data based decision making tool which

per drydock in unplanned growth costs if they were

emphasizes the disciplined use of facts, data, and sta 

to make reliable drydock plans, create precise speci 

tistical analysis.  First, Six Sigma is a statistical mea 

fications, and identify most repair items.  The imple 

surement. Secondly, it is a business strategy to achieve

mentation of Six Sigma in ship operations will im 

virtually defect free, first time quality; and thirdly, it is

prove safety and customer satisfaction, and reduce

a  philosophy  to  create  the  breakthrough  thinking

maintenance costs.

needed for major process changes.  On the other hand,

Lean Manufacturing emphasizes scheduling methods,

speed, simplification, and one piece flow.

Six Sigma and Lean Manufacturing in

Through  the  integration  of  both  processes,  it  is

Shipbuilding

planned to demonstrate that productivity will be in 

creased, manufacturing costs driven downward, cycle

The University of New Orleans, College of Engi 

times reduced, quality increased, and the overall health

neering is sponsoring a Six Sigma and Lean Manu 

of the U.S. shipbuilding industry improved (Figure 3 2

facturing project within the shipbuilding industry.

shows the integration of the two principles).  NGSS

The integration of Six Sigma and Lean Manufac 

personnel are presently being trained on the principles

turing will improve productivity, decrease manufac 

and processes of Six Sigma and Lean Manufacturing.

turing costs, reduce cycle times, and increase qual 

Twenty four    pilot  projects  have  been  completed  at

ity at U.S. shipyards.

NGSS.  Upon completion of this project, UNO COE s

Advanced Maritime Technology Application Center will

The  University  of  New  Orleans,  College  of

publish final findings of the results of the pilot projects,

Engineering s Advanced Maritime Technology Appli 

make  recommendations  for  future  Six  Sigma/Lean

cation Center has begun a project to incorporate the

Manufacturing  efforts  and  continue  to  assist  NGSS

principles of Six Sigma and Lean Manufacturing within

personnel in their improvement efforts.  This project

the shipbuilding industry.  This research project is spe 

helped facilitate the spread of Lean Six Sigma through 

cifically targeted at Northrop Grumman Ship Systems

out the NGSS sector by leveraging the project funding.

(NGSS) Avondale and Ingalls Operations.  Through the

Based on the early successes, NGSS has decided to con 

integration of the principles of Lean Manufacturing

tinue and expand the methodology.  The results of this

and the tools of Six Sigma, productivity increases within

research should encourage other shipyards in the U.S.

the shipyards can occur.

to implement this program.

Figure 3 2.  Lean Six Sigma in Shipbuilding

20