Sign up for email updates

To ensure you're always up to date on the latest news and guidance in the Offshore Energies industry sign up.

Email updates
OEUK Case Studies11th Oct 2017

New: Aker Solutions – Kaizen: 5S at Aker Solutions Portlethen Facility

Problem Statement

Excess materials and inventory, HSE issues due to
inventory and the need to hire another property to be
able to service a major contract.

Aim 

To improve the efficiency of the work carried out at the
Aker Solutions Portlethen facility.

Method 

• Map current process and draw out issues preventing the
flow of work through the facility.
• Map future lay out.
• Clear out excess inventory.
• Set-up standardised work areas.
• Reset factory for major contract and for flow
• Install lean tools such as tool shadowing, visual
management and Kanban.

Impact

New process ensured:
• Reduction in motion waste (approx 73% for the most frequent
job type).
• 8.5 tonnes removed – electrical, paperwork, scrap metal.
• £11k retrieved from scrapped items.
• 230m2 space freed-up for potential production bays.
• Potential 70% increase in production with introduction of new
bays.
• Cost avoidance – removing need for additional facility for
Mariner workload: £406K for per year, starting 2017.

The new process resulted in:
• Safer environment with 8.5tonnes of waste removed from site.
• Installed management walk rounds and time to reset and
improve during working day so changes are sustained
• Aker Solutions Portlethen is a more desirable place to work (an
interviewee after a facility tour).
• During a scheduled tour of the facility a customer was
impressed with how “in control” the facility was of production
for their contract.

Total cost avoided: £406k per annum

Contact: Darren Clyde, Senior Lean Coach