Application of Takt and Kanban to Modular Wind Turbine Construction

Abstract

This study focuses on the applicability of Takt planning in combination with Kanban, plan-do-check-act (PDCA)/Deming cycle, and visual management to modular offshore wind turbine construction. The modular offshore wind industry, and in particular an offshore wind project in the British section of the North Sea, faced issues with delivery times, productivity, and uncertainty management (safety and/or pandemic disruptions). The objective of our research was to develop and test a conceptual model that responds to these challenges, which further will increase the likelihood of reducing delays in offshore energy operations. The initial literature review made it evident that few, if any, have covered Takt implementation in modular construction, and certainly not in offshore energy operations. A design science approach was chosen, and in collaboration with the case organization, the model was constructed and evaluated in a longitudinal field study. The application of mixed methods ensured data input originating from practical experience provided by field experts both within and outside the case-study organizations, theoretical knowledge from academics, and state-of-the-art literature allowed the development of a model that embeds Kanban, Takt, and PDCA to the context of modular offshore wind turbine tower construction. After its implementation, a 10% increase in labor productivity was recorded. Furthermore, through the stable productivity measures in a time of crisis, the model revealed its robustness during COVID-19. The contributions to the body of knowledge are the developed model combining Takt, Kanban, and PDCA, and the visual management interface. The model was implemented together with the visual management interface to achieve a flexible planning framework that can respond to challenges with delivery times and productivity and withstand major disruptions, such as the COVID-19 pandemic.