{"id":28093,"date":"2024-12-04T13:23:26","date_gmt":"2024-12-04T06:23:26","guid":{"rendered":"https:\/\/solwer.com\/?p=28093"},"modified":"2024-12-04T13:43:09","modified_gmt":"2024-12-04T06:43:09","slug":"lean-automation-eliminating-the-7-wastes-in-production-systems","status":"publish","type":"post","link":"https:\/\/solwer.com\/en\/lean-automation-eliminating-the-7-wastes-in-production-systems\/","title":{"rendered":"LEAN Automation: Eliminating the 7 Wastes in Production Systems"},"content":{"rendered":"\t\t
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LEAN Automation: Eliminating the 7 Wastes in Production Systems<\/h1>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
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The integration of automation in factories to boost productivity and reduce costs is both a key goal and a challenge for factory managers, especially those aiming to develop a Smart Factory to meet the growing market demands. However, transforming a factory into a smart one isn\u2019t just about investing in expensive machinery or advanced robots. More importantly, it involves preparing the workflow before integrating it with automation systems, and LEAN Automation is the key. Today, Solwer will explain what LEAN Automation is and how it benefits industries in the 4.0 era.<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

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\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\"IoT\"\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
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What is Lean Automation?<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
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LEAN Automation combines lean principles with automation systems, focusing on improving production processes to add value for customers. It\u2019s not just about increasing the efficiency of each step, but also considering the benefits customers get from the product while striving to minimize costs.<\/span><\/p>

When people think about automation, they may assume it will increase expenses, conflicting with lean principles aimed at reducing costs. However, the cost reductions in lean are not only financial but also about designing the most cost-effective and efficient processes, without always needing expensive equipment.<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t

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Principles of Lean Automation<\/h2>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
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\n\t\t\t\t\t\t\t\t\t1. Systems Thinking\n\nFocuses on improving the overall value for customers from the product, not just increasing efficiency in individual processes.\n

2. Waste Reduction<\/h3>\nUses automation technology to reduce various wastes, such as errors, waiting times, and unnecessary movements, through systematically designed processes.\n

3. Right-Sizing Investment<\/h3>\nThere\u2019s no need to heavily invest in automation for every process. Invest only in areas that truly add value and reduce waste.\n

4. Flexibility & Responsiveness<\/h3>\nDesign automation systems to be flexible, adapting to changes in market demands and customer needs without halting production.\n

Differences Between Traditional Automation and Lean Automation<\/H2>\n

1. Implementation Goals<\/H3>\nTraditional Automation: Focuses on increasing production capacity by automating repetitive tasks, replacing human labor to reduce errors and increase speed, but does not address unnecessary steps.\nLEAN Automation: Focuses on reducing waste and creating value for customers, improving processes for optimal results, and using automation technology only when necessary to enhance efficiency.\n

2. Cost Reduction Methods<\/H3>\nTraditional Automation: Reduces long-term costs by replacing human labor with machines to produce more in the same or shorter time, though initial investment may be high.\nLEAN Automation: Reduces costs at every step by improving processes to be more efficient, using resources effectively, and investing only where necessary, without always needing costly new technologies.\n

3. Production Flexibility<\/H3>\nTraditional Automation: Typically designed for repetitive tasks or mass production, offering limited flexibility for change.\nLEAN Automation: More flexible, as it is designed to adapt to specific, diverse production needs and market changes without halting production.\n

4. Focus on Process Improvement<\/H3>\nTraditional Automation: Emphasizes increasing output and reducing costs by replacing human labor without focusing on eliminating non-value-added steps.\nLEAN Automation: Focuses on continuous process improvement, eliminating unnecessary steps, and increasing efficiency by automating only the necessary tasks.\n

5. Technology Investment<\/H3>\nTraditional Automation: Often involves significant investment in machines or systems for repetitive tasks.\nLEAN Automation: Invests in technology that aligns with processes that need actual improvement, ensuring cost-effective usage of technology.\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
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Effective Lean Automation Design by Denso<\/H2>\nDenso places great importance on preparation and system design as the foundation for effective automation. Lean Automation design isn\u2019t just about replacing people with robots; it also incorporates human skills in designing automation systems. The first step is to eliminate \u201cMuda,\u201d or waste, in the workflow. Using the Lean Manufacturing concept, it identifies 7 key wastes: Overproduction, Inventory, Transportation, Motion, Processing, Delay, and Defects. These wastes should be eliminated to ensure streamlined, efficient, and continuous processes.\nFollowing Lean Automation principles, system design focuses on reducing waste while enhancing productivity. As Sato Kenshu states, \u201cThe best production process is one that is simple and continuous.\u201d Understanding Lean Automation principles helps organizations design and improve systems that quickly respond to market demands, reduce costs, and create a competitive advantage.\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
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\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\"Manufacturing\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
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\n\t\t\t\t\t\t\t\t\tOrigin of Lean Automation System Integrators (LASI)<\/H3>\nIn 2018, DENSO and DENSO WAVE launched the Lean Automation System Integrator (LASI) training program for Connected Industries as part of their support for manufacturing in Thailand.\nThis program encapsulates over 70 years of experience and expertise in automation, developed through manufacturing activities, to train system integrators capable of implementing highly efficient and lean automation systems in production processes. In this program, automation is not just about replacing human labor with robots; it also involves teaching the steps to achieve high-efficiency automation, including robot installation after process efficiency improvements. It is done in close cooperation with the Thai government, universities, and educational institutes. This program is helping to train system integrators in robotics and IoT, both of which are core pillars of the Thailand 4.0 model.\n

Steps to Implement Lean Automation in Factories<\/H2>\n

1. Process Analysis<\/H3>\nStudy the entire production process to identify current issues, such as waste in various steps, or inefficient use of time or resources. Create process maps to identify non-value-adding or problematic steps, including areas where automation could improve.\n

2. Define Lean Objectives<\/H3>\nSet clear goals, such as reducing production time, lowering costs, minimizing human error, or improving product quality. Identify KPIs (Key Performance Indicators) to track the results of Lean Automation implementation.\n

3. Process Redesign<\/H3>\nSimplify and make processes more efficient by eliminating unnecessary steps and combining processes that can be done together to reduce time and resource wastage. Consider automating repetitive tasks or those requiring high precision, such as assembly, packaging, or quality inspection.\n

4. Select Appropriate Automation Technology<\/H3>\nChoose automation technologies that meet the needs, such as robotic arms, sensor-based inspection systems, data analysis software, or IoT systems to connect production data and processes. Focus on selecting cost-effective technologies that provide value, without necessarily opting for high-end, expensive solutions unless they meet the specific cost-reduction needs.\n

5. Pilot Testing<\/H3>\nTest the Lean Automation system in a specific area of the factory to evaluate its suitability for real-world use. Check whether the system reduces waste, improves accuracy, and meets the set process improvement goals, adjusting for any issues that arise during the test phase.\n

6. Employee Training<\/H3>\nTrain employees to understand how to operate Lean Automation systems and maintain equipment, ensuring they can use the system effectively. Create an understanding of Lean principles so all employees focus on waste reduction and adding value in production processes.\n

7. Full-scale Implementation<\/H3>\nImplement Lean Automation across the entire production process according to the plan tested. Install sensors and tracking systems to collect operational data, helping management monitor results and continuously improve operations.\n

8. Monitoring and Continuous Improvement

\nMonitor the performance of Lean Automation using collected data, such as production time, waste reduction, and work efficiency. Continuously improve processes based on KPI evaluation, seeking ways to reduce further waste.\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
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\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\"Industrial\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t
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Benefits of Lean Automation in Factories<\/H2>\nImplementing Lean Automation in factories or businesses offers numerous benefits, including increased production efficiency, resource management, waste reduction, and value creation for customers in various ways:\n

1. Waste Reduction<\/H3>\nLean Automation focuses on eliminating non-value-adding steps and waste in the process, such as unnecessary movements, excess inventory, and redundant resource use. It also reduces human errors in production, leading to more consistent processes and higher product quality.\n

2. Increased Productivity<\/H3>\nAutomation speeds up production processes, allowing for more goods to be produced in less time. It reduces wait times and minimizes the time spent on each step, resulting in a smoother and more efficient overall production flow.\n

3. Cost Savings<\/H3>\nLean Automation reduces the use of unnecessary resources and improves raw material efficiency, lowering production costs. It also reduces reliance on human labor for repetitive tasks, cutting labor costs and enabling employees to focus on more valuable work.\n

4. Enhanced Product and Service Quality<\/H3>\nAutomated systems offer precision in execution, reducing human errors and ensuring consistent product quality. Systems can also monitor and control quality in real-time, allowing for early identification of issues.\n

5. Flexibility in Production<\/H3>\nLean Automation allows factories to quickly adjust production to meet customer demands, such as changing the quantity or type of product. It enables manufacturers to efficiently respond to market changes without stopping production.\n

6. Competitive Advantage<\/H3>\nLean Automation helps factories produce goods more efficiently and cost-effectively, allowing for on-time delivery and high-quality products, thereby enhancing competitiveness in the market. Its flexibility and efficiency enable companies to respond more quickly, improving their chances of gaining market share.\n

7. Improved Workforce Utilization<\/H3>\nLean Automation allows employees to focus on more complex, higher-value tasks instead of repetitive work, increasing their skills and knowledge. It reduces fatigue and risks associated with dangerous or repetitive tasks, creating a safer work environment.\n

8. Data-driven Insights<\/H3>\nLean Automation integrates with IoT systems and various sensors, enabling detailed data collection on production and operations. This data helps management make precise decisions, enhancing planning and continuous process improvement.\nLean Automation is not just about using automation technology at every point; it aims to develop processes that add value, reduce waste, and improve overall efficiency, making it easier to meet market and customer demands. While automation technology requires significant investment, it’s important to conduct thorough research to ensure it is cost-effective. Lean Automation enables thoughtful system design, reducing costs (Low-cost Automation) while increasing production efficiency (High Productivity) for sustainable production line improvements.\nReference:\nLean Automation \u0e04\u0e37\u0e2d\u0e2d\u0e30\u0e44\u0e23 \u0e41\u0e25\u0e30\u0e40\u0e14\u0e47\u0e19\u0e42\u0e0b\u0e48\u0e17\u0e33\u0e43\u0e2b\u0e49\u0e21\u0e35\u0e1b\u0e23\u0e30\u0e2a\u0e34\u0e17\u0e18\u0e34\u0e20\u0e32\u0e1e\u0e44\u0e14\u0e49\u0e2d\u0e22\u0e48\u0e32\u0e07\u0e44\u0e23? – Lean Lab Solution\nLean Automation \u0e23\u0e30\u0e1a\u0e1a\u0e2d\u0e31\u0e15\u0e42\u0e19\u0e21\u0e31\u0e15\u0e34\u0e41\u0e1a\u0e1a\u0e25\u0e35\u0e19\u0e43\u0e19\u0e2d\u0e38\u0e15\u0e2a\u0e32\u0e2b\u0e01\u0e23\u0e23\u0e21\u0e01\u0e32\u0e23\u0e1c\u0e25\u0e34\u0e15\nLASI (Lean Automation System Integrators) | DENSO WAVE\nThe 7 Wastes \u0e01\u0e32\u0e23\u0e25\u0e14\u0e04\u0e27\u0e32\u0e21\u0e2a\u0e39\u0e0d\u0e40\u0e2a\u0e35\u0e22 7 \u0e1b\u0e23\u0e30\u0e01\u0e32\u0e23\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t<\/section>\n\t\t\t\t<\/div>\n\t\t","protected":false},"excerpt":{"rendered":"

LEAN Automation: Eliminating the 7 Wastes in Production Systems The integration of automation in factories to boost productivity and reduce costs is both a key goal and a challenge for…<\/p>\n","protected":false},"author":1,"featured_media":28082,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[1],"tags":[244],"class_list":["post-28093","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-general","tag-lean-automation-manufacturing-process"],"aioseo_notices":[],"_links":{"self":[{"href":"https:\/\/solwer.com\/en\/wp-json\/wp\/v2\/posts\/28093"}],"collection":[{"href":"https:\/\/solwer.com\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/solwer.com\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/solwer.com\/en\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/solwer.com\/en\/wp-json\/wp\/v2\/comments?post=28093"}],"version-history":[{"count":4,"href":"https:\/\/solwer.com\/en\/wp-json\/wp\/v2\/posts\/28093\/revisions"}],"predecessor-version":[{"id":28099,"href":"https:\/\/solwer.com\/en\/wp-json\/wp\/v2\/posts\/28093\/revisions\/28099"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/solwer.com\/en\/wp-json\/wp\/v2\/media\/28082"}],"wp:attachment":[{"href":"https:\/\/solwer.com\/en\/wp-json\/wp\/v2\/media?parent=28093"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/solwer.com\/en\/wp-json\/wp\/v2\/categories?post=28093"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/solwer.com\/en\/wp-json\/wp\/v2\/tags?post=28093"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}