Agility, productivity, efficiency\u2026 these are words that constantly resonate in the minds of business and production plant managers. Countless pages have been written to describe methodologies aimed at achieving these goals, and a significant portion of that ink has been dedicated to writing about “Lean Manufacturing.” <\/p>\n
Here, we do not use ink\u2014after all, we are paperless<\/a>\u2014but we have certainly put our keyboards to work to bring you some of the fundamental applications of Lean Manufacturing<\/a>. Let\u2019s begin! <\/p>[\/et_pb_text][et_pb_text _builder_version=”4.16″ text_font=”|300|||||||” min_height=”28px” custom_margin=”||20px|||” custom_padding=”||0px|||” global_colors_info=”{}”] Lean Manufacturing, or lean production, is a philosophy focused on eliminating anything that does not add value within the production chain. Its implementation leads to higher-quality products<\/a> and more agile, efficient processes. <\/p>\n This is a concept we have already discussed extensively in other articles, but it is always useful to refresh some key insights as a prelude to exploring its practical application.<\/p>[\/et_pb_text][et_pb_button button_url=”https:\/\/puntazo.sixphere.com\/hacia-la-fabrica-inteligente\/” url_new_window=”on” button_text=”Discover the path to the smart factory” button_alignment=”center” _builder_version=”4.16″ global_colors_info=”{}”][\/et_pb_button][et_pb_text _builder_version=”4.16″ text_font=”|300|||||||” global_colors_info=”{}”] To develop the principles and methodologies of Lean Manufacturing in the industry, there is a wide range of possibilities, techniques, and tools. Among them, we will highlight: <\/p>[\/et_pb_text][et_pb_text _builder_version=”4.16″ text_font=”|300|||||||” global_colors_info=”{}”] This concept, also known by its English term, Value Stream Mapping (VSM), involves graphically representing all the procedures that take place in the manufacturing process through a diagram.<\/p>\n In this way, we can carefully analyze each step, determining whether it truly adds value and, if not, modifying or eliminating it. Special attention should be paid to transfers between stages, as this is often where the greatest waste occurs. <\/p>[\/et_pb_text][et_pb_text _builder_version=”4.16″ text_font=”|300|||||||” header_font=”||||||||” global_colors_info=”{}”] We know that Industry 4.0<\/a> is meaningless without data; it becomes just words with no practical value. Some of these metrics include: <\/p>[\/et_pb_text][et_pb_text _builder_version=”4.16″ text_font=”|300|||||||” min_height=”130px” custom_margin=”||20px|||” custom_padding=”||0px|||” global_colors_info=”{}”] This wide range of key parameters must be properly recorded, processed, and presented in such a way that we can make simple decisions while achieving significant results for the factory’s productivity<\/a>.<\/p>[\/et_pb_text][et_pb_text _builder_version=”4.16″ text_font=”|300|||||||” custom_margin=”7px|||||” custom_padding=”0px|||||” global_colors_info=”{}”] In this manufacturing system, also known as pull, production volumes are determined by demand, meaning that items are only produced when there are orders to fulfill.<\/p>\n With demand-driven production, a more flexible production process is achieved, making it adaptable to potential future changes. It also allows for greater scalability of equipment based on the project and reduces costs in raw materials and storage.<\/p>[\/et_pb_text][et_pb_image src=”https:\/\/puntazo.sixphere.com\/wp-content\/uploads\/2020\/02\/Lean-Manufacturing-en-tu-empresa.jpg” alt=”Lean Manufacturing in your company” _builder_version=”4.16″ global_colors_info=”{}”][\/et_pb_image][et_pb_text _builder_version=”4.16″ global_colors_info=”{}”] The Just in Time concept is closely linked to the pull production system we just discussed.<\/p>\n With demand-driven production, we manufacture smaller batches, which allows for more meticulous control of the associated quality parameters. As a result, manufacturing waste is reduced, and we are able to strictly meet the planned deadlines.<\/p>[\/et_pb_text][et_pb_text _builder_version=”4.16″ text_font=”|300|||||||” global_colors_info=”{}”] This philosophy of the 5S is primarily based on the concept of standardization. Well-defined and standardized processes tend to have fewer errors and complications. Its name comes from the Japanese initials of the five steps required for its implementation, which are: <\/p>\n <\/p>\n If you wish to dive deeper into each of these steps and the world of 5S, we invite you to read 5S and Poka Yoke in Industry: Improving Process Quality<\/em><\/a>.<\/p>[\/et_pb_text][et_pb_text _builder_version=”4.16″ text_font=”|300|||||||” min_height=”86px” custom_margin=”||-24px|||” custom_padding=”||0px|||” global_colors_info=”{}”] This Kanban technique<\/a> primarily consists of two key elements:<\/p>\n <\/p>\n The cards, which can be physical or preferably virtual, are associated with each part and record useful information for the operators in charge of it. This information could range from a description to its origin, destination, dates, and more. <\/p>\n On the other hand, the Kanban board is divided into columns, each representing the status of each part within the production chain.<\/p>[\/et_pb_text][et_pb_text _builder_version=”4.16″ text_font=”|300|||||||” global_colors_info=”{}”] This Lean principle is based on the idea that a machine change within a production line should not exceed a total of 10 minutes, providing a significant increase in flexibility.<\/p>\n To implement this, the design must distinguish between the times related to operations that can be performed while the machine is stopped (internal) and those that can be done while the machinery is running (external).<\/p>[\/et_pb_text][et_pb_text _builder_version=”4.16″ text_font=”|300|||||||” global_colors_info=”{}”] Although the demands for quality and productivity are high in any industry, in some, such as aerospace<\/a>, due to its specific characteristics, these requirements reach extremely high levels.<\/p>\n We are talking about a mode of transportation where safety must prevail, which leads to the pursuit of perfection in every part and component of the aircraft.<\/p>\n From our own experience, we can discuss how we have successfully facilitated the implementation of Lean Manufacturing measures at Alestis Aerospace<\/a>, one of the three TIER 1 companies operating in Spain, through the implementation of Polaris Industry.<\/p>[\/et_pb_text][et_pb_text _builder_version=”4.16″ text_font=”|300|||||||” global_colors_info=”{}”] The concepts of Shipyard 4.0<\/a> and Port 4.0<\/a> (also known as Smart Port) are becoming increasingly prevalent. In this context, Lean Manufacturing also has much to contribute, as the quality standards in this field are also extremely high. <\/p>\n Public institutions are not unaffected by this situation and are therefore actively developing measures to drive the digitalization of the naval sector. On one hand, there is the Port 4.0 Plan<\/a> for the digital transformation of Spanish ports, as well as the Shipyard 4.0 Digital Transformation Plan<\/a>. <\/p>[\/et_pb_text][et_pb_text _builder_version=”4.16″ text_font=”|300|||||||” global_colors_info=”{}”] One of the sectors that can benefit the most from Lean methods is the agrifood industry. Climate change and the ever-growing global population demand maximizing the efficiency of agrifood resources to their highest potential.<\/p>\n In this specific case, we can classify the wastes of Lean Farming as:<\/p>\n In order for agrifood industries to optimize their resources, we have made available Polaris Farm, a specific module of Polaris that is flexible, automated, interconnected, and intelligent, designed to improve the agricultural production system. It is worth noting that thanks to Polaris Farm, we received support from the DIVA Project<\/a>. <\/p>\n You have seen how Lean Manufacturing is a very broad, versatile, and adaptable working methodology for any production environment. To implement it, you will need powerful tools that allow you to unlock its full potential, and we are here to help you with that. <\/p>[\/et_pb_text][\/et_pb_column][\/et_pb_row][et_pb_row column_structure=”2_5,3_5″ _builder_version=”4.18.0″ _module_preset=”default” background_color=”rgba(224,153,0,0.12)” custom_margin=”40px||40px||false|false” custom_padding=”20px|20px|30px|20px|false|false” global_colors_info=”{}” theme_builder_area=”post_content”][et_pb_column type=”2_5″ _builder_version=”4.18.0″ _module_preset=”default” global_colors_info=”{}” theme_builder_area=”post_content”][et_pb_image src=”https:\/\/puntazo.sixphere.com\/wp-content\/uploads\/2022\/05\/help.png” alt=”We assist your data design and analysis process” title_text=”We assist your data design and analysis process” _builder_version=”4.18.0″ _module_preset=”default” global_colors_info=”{}” theme_builder_area=”post_content”][\/et_pb_image][\/et_pb_column][et_pb_column type=”3_5″ _builder_version=”4.18.0″ _module_preset=”default” global_colors_info=”{}” theme_builder_area=”post_content”][et_pb_text _builder_version=”4.18.0″ _module_preset=”default” header_font=”Oswald|300|||||||” header_text_align=”center” header_text_color=”#FFFFFF” header_2_font=”Oswald|300|||||||” header_2_text_align=”left” header_2_text_color=”#000000″ global_colors_info=”{}” theme_builder_area=”post_content”]How is Lean Manufacturing Defined?<\/h2>[\/et_pb_text][et_pb_text _builder_version=”4.16″ text_font=”|300|||||||” header_font=”||||||||” header_font_size=”35px” header_2_font=”||||||||” header_2_font_size=”30px” header_3_font=”||||||||” header_3_font_size=”25px” min_height=”31px” custom_margin=”|-3px||||” global_colors_info=”{}”]
How to Apply Lean Manufacturing?<\/h2>[\/et_pb_text][et_pb_text _builder_version=”4.16″ text_font=”|300|||||||” global_colors_info=”{}”]
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1. Create a value stream map<\/h3>[\/et_pb_text][et_pb_text _builder_version=”4.16″ text_font=”|300|||||||” min_height=”61px” custom_margin=”-24px|||||” global_colors_info=”{}”]
2. Data management<\/h3>[\/et_pb_text][et_pb_text _builder_version=”4.16″ text_font=”|300|||||||” custom_padding=”||0px|||” global_colors_info=”{}”]
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3. Demand-Driven production<\/h3>[\/et_pb_text][et_pb_text _builder_version=”4.16″ text_font=”|300|||||||” global_colors_info=”{}”]
4. Just in time<\/h3>[\/et_pb_text][et_pb_text _builder_version=”4.16″ text_font=”|300|||||||” global_colors_info=”{}”]
5. 5S<\/h3>[\/et_pb_text][et_pb_text _builder_version=”4.16″ text_font=”|300|||||||” custom_padding=”||0px|||” global_colors_info=”{}”]
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6. Kanban<\/h3>[\/et_pb_text][et_pb_text _builder_version=”4.16″ text_font=”|300|||||||” global_colors_info=”{}”]
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7. Single Minute Exchange of Die (SMED)<\/h3>[\/et_pb_text][et_pb_text _builder_version=”4.16″ text_font=”|300|||||||” global_colors_info=”{}”]
Applications in different industries<\/h2>[\/et_pb_text][et_pb_text _builder_version=”4.16″ text_font=”|300|||||||” global_colors_info=”{}”]
Applying Lean Manufacturing in Aerospace<\/h3>[\/et_pb_text][et_pb_text _builder_version=”4.16″ text_font=”|300|||||||” global_colors_info=”{}”]
Applying Lean Manufacturing in naval management<\/h3>[\/et_pb_text][et_pb_text _builder_version=”4.16″ text_font=”|300|||||||” global_colors_info=”{}”]
Applying Lean Manufacturing in the agrifood sector<\/h3>[\/et_pb_text][et_pb_text _builder_version=”4.16″ text_font=”|300|||||||” global_colors_info=”{}”]
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FREE EBOOK<\/strong><\/span>: OEE Efficiency in Semi-Automated Production Lines<\/h2>\nDiscover the details of the OEE indicator, how to automate its calculation and the requirements your production processes must meet to implement it.[\/et_pb_text][et_pb_code _builder_version=”4.18.0″ _module_preset=”default” custom_margin=”20px||||false|false” global_colors_info=”{}” theme_builder_area=”post_content”]\n\t\t\t\t\t\t