Digital Lean: Changes in lean tools with Industry 4.0 technology

New trend is setting in the manufacturing industry. Industry 4.0 revolution, digitalization of the manufacturing industry is changing how we manufacture things. With existing tools and techniques of lean manufacturing we have been familiar with, it suggests there might be disruption because of Industry 4.0. The lean tools are invaluable assets when it comes to sustainability, education and waste reduction in manufacturing. We shouldn’t make sweeping changes in our process based on data alone, so it is important to maintain our lean manufacturing perspective alongside forward-looking Industry 4.0 intelligence and implementing it.

What is Digital Lean?

We are all familiar with famous traditional lean manufacturing that is implemented almost in every field. Its origin dates back to the beginning of the 19th century with the start of Japanese automobile manufacturing. These are sets of principles aiming to minimize waste, increase productivity in work and time. But with changing demands and birth of a new generation of manufacturing systems these are needed to be innovated along.

Hence, Digital lean, enhanced lean principles to make their application more potent.

Digital lean uses Industry 4.0 technology and other digital tools to provide more accurate and timely information about operations.

What is industry 4.0?

Industry 4.0 is a new phase in the Industrial revolution which focuses on digitization. It is not just about investments in the new technologies but about changing or revolutionizing the complete operation of your company or business. It is putting emphasis on the new digital technology with the help of interconnectivity, real-time data and the cyber-physical systems. It offers a more holistic and comprehensive approach to manufacturing.

Some of the basic concepts of Industry 4.0 are:

• Internet of Things (IoT): It is the connection between physical objects fitted with sensors, software etc. and the internet to exchange information and data in order to improve productivity, services and enhance efficiency.
• Industrial Internet of Things (IIoT): It is the extension of IoT in the industrial sector. It basically refers to the connection of people and machines.
• Enterprise Resource Planning (ERP): It is the set of tools used to manage and integrate the information in an organization.
• Cyber-Physical Systems(CPS): These are the systems capable of collaborating the computational entities with the physical world and its processes. It offers real-time data collection and analysis and is also referred to as cyber-manufacturing.
• Smart factory: It is the type of factory that uses Industry 4.0 technologies and approaches.
• Artificial Intelligence (AI): It is the ability of the computer to mimic human abilities of performing tasks, learning, planning etc.
• Machine Learning: It is the ability of the computer to learn and improve using AI without being told to do so.
• Cloud computing: It is basically the availability of computer resources, data storage with use of inter-connected servers on the internet without active management by the user.
• Big Data: It is the large sets of structured and unstructured data growing exponentially which can be organized, compiled, stored and analyzed.
• Machine to Machine (M2M): It is the communication that takes place between two machines through wireless or wired networks.
• Ecosystem: It is the complete connection of all the operations, inventory, planning, customer relationships, finances and the manufacturing execution.

With introducing industry 4.0 technology in traditional lean tools we are extending their usage and reach.

Now, not all lean tools are suppose to 100% coexist with industry 4.0 tech but some are discussed below like -

• Kanban: So, Kanban is a signaling mechanism used to control work and indicate the need for resource replenishment or process status. For example, let’s assume bins are filled with in-process components at a workstation. Once raw materials are used up to a certain specified level, operators from the previous manufacturing steps realize that they have to replenish the bin. Here, Kanban can be implemented for signaling all the actions. Now, with the introduction of Auto-ID technology such as RFID, it can be implemented to track unit level material consumption in real time, starting replenishment activity automatically.
• Total Productive Maintenance (TPM): TPM is a system that optimizes equipment performance and workflows. It is generally performed within a certain time period based on runtime, cycles and other criteria to service equipment before a failure would typically occur. With technology like advanced sensors and machine learning algorithms enable predictive maintenance, where equipment is serviced based on sensor conditions on the equipment (ex. Vibration, force , temperature). This enables extending maintenance intervals while simultaneously reducing failure events. 3
• 3P (production, preparation, process): 3P is a common process in which cross-functional teams use raw physical representations of the manufacturing environments to create new processes and products. As it is a type of an exercise, manufacturers often construct mock-ups of future manufacturing lines, which takes significant space and time and waste.
• Single Minute Exchange of Dies(SMED): It is a system that significantly reduces the time taken to complete equipment changeovers. The main aim behind the process involved in SMED is to reduce the set-up times. A good example of this is the NASCAR pit crew, they designed their team for each step to fulfil the needs during the pit stop which is done in very short time. With AI and machine learning these bottlenecks can be easily predetermined. With the help of sensors and software it is possible for machines to automatically identify products and load the appropriate program and tools. No manual intervention required. And as the changeover is automated, operators can shift their focus on performing value-adding activities. Faster setups means more work to cycle through hence more productivity.

In Conclusion……

As traditional lean has been a success so is digital lean, it’s effective and rich. It minimizes the effort to understand operations along with generating more accurate and timely information. It is enhanced and suits the current digital mindset, changing behaviors, and shifting decision-making away from experience-based to data-based. Moreover, the upfront investment is not necessarily too much for good manufacturing setups hence easy to implement.

With more innovation and technology boom, more changes can be foreseen in future. Hence integration of lean manufacturing tools and industry 4.0 modules together can add considerable value to a manufacturing setup or company.