Introducion of lean management systems integrating technology 4.0 (Part 3)

Of the four groups of elements that make up a lean system, the Control and human factors play the most important role.

Control and human factors

Industry 4.0 is a good platform for implementing TPM (Total Performance Maintenance) with automatic error and failure notification systems. At the same time, the error notification also activates the e-kanban system to rearrange the production plan accordingly. Maintenance staff can refer to the analysis from cloud computing technology to perform preventive maintenance, or repair repeating errors thanks to pre-coded data.

In addition, thanks to RFID, the sensors associated with each device will easily record their status during unplanned downtime, thereby helping managers analyze and find the source causes this situation. On the other hand, Internet of Things applications can integrate information from many different devices to aggregate and devise methods to limit errors in the production process.

Employee involvement

With the application of Industry 4.0, production workers are able to provide immediate feedback and comments in real time via smart phones or tablets. The data can be sent for company-wide collection linked to the use of big data. The evaluation of workers in term of speed, accuracy, performance, and motivation can also be simplified and visualized through specialized interfaces to enhance worker support systems.

How SMEs can integrate lean and Industry 4.0

Through integrating robust Industry 4.0 ICT applications, organizations implementing lean systems will reap the combined benefits of real-time information and waste elimination to enhance the performance of the key supplier, customer, process, and control and human factors.

As cheaper, faster, more flexible robots, sensors, technical solutions, advanced analysis algorithms, and connectivity options become commonly available, the integration of lean and Industry 4.0 could occur sooner than most SMEs expect. Nevertheless, it will involve intensive investment and potentially result in comprehensive changes in organizations.

Most of Industry 4.0’s overall studies have been either theoretical success or in the early trials. Researchers have not been able to make convincing statements about possible solutions to balance costs and benefits in a comprehensive way. Therefore, any organization that wants to access Industry 4.0 needs to equip themselves with knowledge of its applications, and start researching on a small scale and continually improving the way they can controll. Senior management also needs to participate directly and this process to ensure the integration is carried out successfully.

Productivity and Quality Office