Maine Boatbuilder Uses Lean Principles to Build Better Boatbuilders

“We often remind our folks that we are in the ‘people’ business and when we get it right, beautifully crafted Maine built boats go out the front door.  The work that Bill Whittier and the team at Maine MEP have done for Back Cove has further helped to empower our craftsmen and women to identify and resolve barriers to their success as boatbuilders. The result of that effort creates creates exceptional yachts renowned by all, and strengthens the pride that is being a Maine Boatbuilder.” Jason Constantine, President

ABOUT BACK COVE YACHTS.

North End Composites was established in 1972 in Rockland, Maine as a manufacturer of fiberglass composite components for the marine industry.  In 1995 NEC became a sister company to another storied Maine boatbuilder, Sabre Yachts.  The Back Cove Yachts brand was launched in 2003 and today North End Composites employs over 130 boatbuilders who hand craft and distribute recreational cruising powerboats throughout the United States, ranging in length between 34 and 58 feet in length under the Sabre and Back Cove names. 

THE CHALLENGE.

Post pandemic yacht manufacturing has become more complicated with supply chain challenges, labor availability, and ever-increasing buyer expectations for the luxury yachts that we produce.  Semi-custom crafted production boatbuilding does not naturally lend itself to Lean repetitive processes so we need to take advantage of any opportunities to optimize efficiencies within our operation.  Having previously worked with Maine MEP on leadership development, we enlisted their team once more to assist in elevating the awareness of our boatbuilders to the benefits of Lean Manufacturing and Kaizen Events to empower them to solve problems quickly and efficiently to simplify a complex manufacturing operation.

MAINE MEP’S ROLE.

Maine MEP utilized our standard process for introducing Kaizen problem solving to Back Cove. We began with Principles of Lean for 24 Leads, Supervisors and Boat Builders. This was followed by a summer full of Kaizen events focusing on Turnover Reduction, Kaizen Daily Communication Huddles, Gemba Boards and Walks, People Focused Process Improvements, and Improved Overall Communications. Each Kaizen cited the need for Train the Trainer Training, so Maine MEP spent the fall creating a new Workshop and has piloted it at Back Cove. Each of the 23 workshop participants has received 20 hours of experiential Train the Trainer instruction in groups of 8. Each of the 23 have presented a Capstone Presentation of their training skills to their Peers Supervisors and Managers.