This project aimed to redesign the manufacturing process of superyacht doors, platforms, and hatches at Akerboom Yacht Equipment, a subsidiary of Koninklijke De Vries Scheepsbouw. Akerboom’s current sequential, fixed-position manufacturing method results in inefficient space use and physically demanding working conditions. The goal was to develop a standardized manufacturing method and corresponding workstations that improve efficiency, reduce labor hours, and enhance ergonomics without compromising quality.

The research phase involved workflow analysis, ergonomic evaluation, Lean Muda identification, and stakeholder consultations, which revealed non-value-adding activities, layout inefficiencies, and ergonomic risks. Based on these findings, a new manufacturing process was developed, splitting core processes and designing standardized workstations for them.

The concept showed a 23% ergonomic improvement compared to the current state, exceeding the initial 15% target. Lead time simulations demonstrated a reduction of approximately 165.5 hours (26.1%). Financial analysis projected a payback period of approximately four years under full implementation. Furthermore, key stakeholders confirmed the concept’s feasibility, viability, and desirability.

Overall, the project provides a blueprint for a standardized manufacturing approach that delivers shorter lead times, improves ergonomics, and ensures long-term economic benefits for Akerboom.