Application of Lean Thinking to Ship Safety Inspection: A Case Study at Port of Surabaya

• Main Authors: , FAISAL CAHYADI, , Prof. Ir. Sigit Priyanto, M.Sc., Ph.D.
• Format: Theses and Dissertations NonPeerReviewed
• Published: [Yogyakarta] : Universitas Gadjah Mada 2011
• Subjects: ETD
• Online Access: https://repository.ugm.ac.id/91028/; http://etd.ugm.ac.id/index.php?mod=penelitian_detail&sub=PenelitianDetail&act=view&typ=html&buku_id=53741
• Institution: Universitas Gadjah Mada

Lean thinking is a mindset widely used in various industries seeking for efficiency and effectiveness through improvement of process flow and elimination of waste. This research applies lean thinking to ship safety inspection at Port of Surabaya. It aims to investigate the existing procedure, identify wastes and nonvalue- add (NVA) activity within the procedure and ultimately propose a new future state of procedure. Firstly, this research reviewed the concept of lean thinking and its application in many industries. Secondly, it examined data of 520 inspections that have been carried out to 201 ships in the last two years (2009 - 2011) in terms of changes in the number of detected deficiencies. Thirdly, it investigated regulation and guideline relating to the existing procedure. A thorough observation to the actual conduct of inspection in harbour master was also conducted. In addition, 11 marine inspectors and 48 ships officers who have been involved in inspection were interviewed. Fourthly, analyses were conducted using the Value Stream Mapping (VSM) to generate a new future state of inspection procedure. It is found that the existing procedure lacks significant impact in terms of imposing a reduction in the total number of detected deficiency between the earlier and subsequent inspection. Only 37% of the ships experience a reduction, indicating that the performance of inspection is currently at the level of 37 on 100 scales. It was mainly due to the severe violation to the regulation, which was demonstrated by the issuance of ship certificate regardless of corrective action undertaken relating to detected deficiency. Meanwhile, the waste found includes application delay and queue. Detected NVA activity includes duplication of work and the loss of application documents. These problems were due to the excessive use of manual handwriting system. Accordingly, this research recommends two things: first, implementing a computerised system supported by internet connection throughout the conduct of inspection