Japan and the Birth of Modern Shipbuilding

An interesting piece on Construction Physics that examines how Japan transformed discarded American wartime shipbuilding techniques into a revolutionary manufacturing system that captured nearly half the global market by 1970. The story reveals the essential ingredients for industrial dominance: government backing, organizational alignment, relentless will to improve, and the systematic coordination needed to turn existing technologies into something entirely new. A few excerpts: During WWII, the US constructed an unprecedented shipbuilding machine. By assembling ships from welded, prefabricated blocks, the US built a huge number of cargo ships incredibly quickly, overwhelming Germany's u-boats and helping to win the war. But when the war was over, this shipbuilding machine was dismantled. Industrialists like Henry Kaiser and Stephen Bechtel, who operated some of the US's most efficient wartime shipyards, left the shipbuilding business. Prior to the war, the US had been an uncompetitive commercial shipbuilder producing a small fraction of commercial oceangoing ships, and that's what it became again. At the height of the war the US was producing nearly 90% of the world's ships. By the 1950s, it produced just over 2%.

But the lessons from the US's shipbuilding machine weren't forgotten. After the war, practitioners brought them to Japan, where they would continue to evolve, eventually allowing Japan to build ships faster and cheaper than almost anyone else in the world.

The third strategy that formed the core of modern shipbuilding methods was statistical process control. The basic idea behind process control is that it's impossible to make an industrial process perfectly reliable. There will always be some variation in what it produces: differences in part dimensions, material strength, chemical composition, and so on. But while some variation is inherent to the process (and must be accepted), much of the variation is from specific causes that can be hunted down and eliminated. By analyzing the variation in a process, undesirable sources of variation can be removed. This makes a process work more reliably and predictably, reducing waste and rework from parts that are outside acceptable tolerances.

Read more of this story at Slashdot.