What do you do if your Lean Manufacturing processes need to integrate new technology?

The most problems that have been happening to integration new technology on company is bellow. (Problem ) 1. Adaptation the new technology with the human interface. 2. Apply simulation in accordance the Mass production condition. (How soluction) 1. Company need investiment on new technology education (Hard skill) + (softskill) of employees 2. Planing the simulation based of pilot line, process or pilot procedures. - try to test on same condition of mass. (Feedback evaluation) 1. Check if the technology results 2. Check the technology to user ( employees) 3. Check customer Feedback also.

It is imperative that you do not rush to introduce technology that will be counter productive. Lean is about optimizing processes, increasing operational efficiencies and motivating employees through Continuous Improvement. The common mistake is introducing technology without fully understanding what question and problem are you going to solve. This approach leaves people behind and it is completely against lean principles, as lean is people-centric. Technology should not bring complexity as lean supports simple efficient and effective processes. Simplicity, practicality and solving or improving peoples problems is key when it comes to lean and technology.

Lean is prerequisite and technology is accelerator. Without the fusion of both, it is merely impossible to stay competitive. The manufacturing landscape is changing where Lean + Technology + Digitalisation is emerging with lots of opportunities.

Avalio minuciosamente suas necessidades de fabrica??o e identifique as áreas onde há desperdícios ou gargalos que precisam ser resolvidos. Analiso como a tecnologia em quest?o pode resolver esses problemas identificados. Considere sua eficácia na redu??o de desperdícios e no aumento da eficiência operacional. Integro a tecnologia de forma gradual, come?ando por áreas específicas onde ela pode trazer o maior impacto positivo. Isso ajuda a mitigar riscos e facilita a adapta??o dos funcionários. Certifico-me de que minha equipe esteja devidamente treinada e capacitada para usar a nova tecnologia de forma eficaz. Isso garante uma transi??o suave e maximiza os benefícios. Acredito que seu eu seguir essas etapas consigo resolver problemas.

Selection of Best technology, its Planning, Planning integration with existing setup is the main part otherwise we have to pay heavy loss at the end. Because integration of new technology will require heavy investments and we have to plan all objectives, integration at shop floor, Layouts etc. in advance. Next is manpower training about the new technology through new technology is must otherwise even after heavy investment we will not extract the required benefits.

La planeación es la herramienta que te ayuda a realizar una implementacion exitosa. Debes considerar todos los puntos para que esta implementacion sea exitosa, puntos como puede ser capacitacion a personal, infrastructura necesaria en el lugar de trabajo. Integrar el mantenimiento a el sistema, etc.

Elegiría comenzar con el paso 1, "Assess Needs" (Evaluar necesidades). Este es un punto de partida crucial porque permite identificar las áreas específicas que podrían beneficiarse de la incorporación de nuevas tecnologías. Este análisis inicial ayuda a asegurar que las inversiones en tecnología sean estratégicas y alineadas con los objetivos globales de la organización, optimizando recursos y maximizando los beneficios potenciales. Además, entender las necesidades actuales y cómo pueden ser mejoradas con tecnología es esencial para planificar los siguientes pasos de manera efectiva.

The next step is to plan the integration of new technologies strategically and aligned with business objectives. This requires a detailed plan addressing aspects such as required resources, implementation timeline, and risk assessment. Methods 5W2H can be applied to ensure a systematic approach. For example, when planning the integration of a connected machinery monitoring system (IoT), it's essential to consider factors like interoperability with existing systems and cybersecurity requirements.

Whenever you've recognized the right innovation to address your issues, plan its coordination carefully. Consider how it will squeeze into existing work processes and what changes will be important to oblige it. This could include retraining staff, changing creation timetables, or in any event, updating work area designs. The key is to limit interruption while guaranteeing that the new innovation improves your Lean Assembling processes, instead of muddling them.

We may need to establish a controlled environment for pilot testing, allowing us to assess the new technology's performance in real-world conditions. This might entail creating dedicated test facilities or utilizing resources within existing production facilities. In this Pilot Testing phase, it's crucial to consistently monitor the technology's performance, gathering data and feedback from employees and stakeholders. This will help evaluate its effectiveness against defined objectives and KPIs, identifying areas for improvement or optimization. Based on insights from pilot testing, we should make necessary adjustments to the implementation plan or the technology itself and mitigate risks of failure during full-scale implementation.

Beside seeing actual simulation impact, these steps are very crucial to ensure communication is reached exactly to those who need to clearly understand. At the same time, reviewing the process if there is any optimization is needed.

After planning, it's crucial to conduct a pilot test to validate the effectiveness of new technologies in a controlled environment. This allows identifying potential challenges and making adjustments before full-scale implementation. During the pilot test, it's essential to involve the operational team to ensure a comprehensive understanding of the technology and gather valuable feedback for future refinements. For example, when testing new production management software, the team can provide insights into usability and integration with existing processes.

Pilot testing is where the previous efforts in cell design and standardized work get put to the test and refined. Many small iterations allow you to find failure points prior to a full investment and significant downtime.

Desde el minuto 1, la elección del equipo es importante, entre los miembros siempre debe estar al que le afectan los problemas y por tanto los cambios. Si no trabajamos con un equipo, la experiencia me dice que viajamos solos y a la deriva y si un proyecto llega a éxito, será pura casualidad. El trabajo en equipo ya no solo enriquece todo el proceso, sino que hace que el proceso siga el flujo natural sin bloqueos

Team engagement is the most important part of Success that will lead to lean the processes through adoption of new Technology. New Technology definitely leverages processes but it is the team's motivation and aspiration that can help in achieving desired results.

engaging team in getting their confidence and making them to own the change to be part of the change will bring good acceptance and results

Esta parte puede ser la más importante . Conozco Industrias donde la mejora no se siente como un requerimiento permanente que debería ser transversal en todos los procesos de la cadena , si no como el de un área que a pesar de llevar un ambicioso nombre como el de excelencia operacional, toma decisiones aisladas , y por ende , erradas. Es más , muchas veces se cae en el error de adquirir tecnologías sin corregir previamente todos los temas de desperdicios y variaciones haciendo que se hagan inversiones que probablemente, no eran necesarias. He visto comprar máquinas que no se necesitaban. Créanme, casos de la vida real.

It's vital to fully engage and get the deeper thoughts of the people involved. It's easy to get people nodding their agreement but getting a deeper level of ownership is key to a successful investment.

In my opinion Continuous improvement is a base principle of Lean Manufacturing and must be applied continuously. New technology must be included in the process The change must be managed by monitoring KPI. There is also need to improve team also to adopt new process and idea.

Lean manufacturing is focused on continuous improvement if you have identified that you need to integrate technology consider doing a Kaizen to identify waste in your process this will help you to avoid automating waste. A value stream map can help you identify areas of improvement within the process, the areas identified ca then be optimized before technology is integrated.

Uma forma clara de entendimento: a filosofia Lean Manufacturing destaca a importancia da melhoria contínua. Após a integra??o da tecnologia, é essencial manter um ciclo de monitoramento e otimiza??o constante. Incentivar o feedback da equipe e estar aberto a melhorias iterativas é fundamental. Esse compromisso contínuo garante que as opera??es de manufatura permane?am ágeis e adaptáveis às mudan?as nas demandas do mercado. A abordagem proativa para aprimorar constantemente os processos é essencial para o sucesso a longo prazo no contexto competitivo da indústria.

Continuous improvement is a fundamental principle of Lean Manufacturing and should be applied continuously after integrating new technologies. This involves regularly monitoring performance indicators and seeking optimization opportunities.

Após a implementa??o inicial da tecnologia, mantenha um processo contínuo de monitoramento do desempenho, buscando oportunidades para otimizar ainda mais sua integra??o nos processos de fabrica??o. Incentive ativamente o feedback da equipe, dando espa?o para que compartilhem suas experiências e sugest?es de melhorias. Esteja preparado para realizar ajustes iterativos com base nessas contribui??es, visando aprimorar continuamente a eficiência e a eficácia operacional. Esse compromisso com a melhoria contínua garante que suas opera??es de manufatura permane?am ágeis e enxutas, capazes de se adaptar às mudan?as nas demandas do mercado.

Finally, it's crucial to conduct an impact assessment to measure the results achieved after integrating new technologies. This involves comparing performance indicators before and after implementation, such as productivity, quality, and cycle time. For example, when implementing an artificial vision system for quality inspection, the impact assessment may reveal a significant reduction in the number of defects and an improvement in customer satisfaction.

Some of my past professional experiences gave me the feeling that introducing new technology was like follow a fashion trend. Automation push, benchmark with competitors, public events,… push to evaluate this opportunity without thinking how much disrupting this change may be. That’s why a preliminary impact analysis should occur before the study of the technology. And of course a second one will be necessary after the deployment.

When it comes to evaluating the impact of new technology on your Lean Manufacturing processes, it's crucial to take a thorough and objective approach. By carefully analyzing key performance indicators, you can determine whether the technology is truly driving efficiency, reducing waste, and increasing value for the customer. This comprehensive assessment will provide a clear view of the implementation's success and help guide future adjustments or technological improvements. Always remember to maintain a focus on continuous improvement and adapting to the evolving needs of the market.

That's a great approach! Keeping track of our processes allows us to have a clear view of what worked and what didn't. It helps us maximize what worked well and minimize what wasn't effective.

A typical impact measurement should include the measurement of the effectiveness and the efficience on the considered process and as well on following processes/steps before being considered as fully effective.

Here is the thing: everyone wants to jump immediately to software solutions. I get it, but there are many reasons why you should not immediately jump to technology. There is a lot to be learned by piloting manual methods before automating or placing your trust in someone else’s programing and calculations. So, before integrating heavy technology, try “lead CAD…” ie, get out a pencil and paper, or erasable pen on whiteboards and start collecting data. Verify and validate everything. Learn the calculations. Understand the process and the metrics and how things operate/ perform. Draw graphs by hand. Encourage everyone else to, too. This way when you decide to automate you have a better shot at getting it right, and automating the right things.

We have to clearly communicate the reasons for integrating new technology, the benefits it will bring, and how it will impact employees' roles and responsibilities. Here we should offer exhaustive training programs to equip employees with the necessary skills and knowledge to use the new technology effectively. Next, we need to identify and address any resistance to change by addressing concerns, providing support, and emphasizing the benefits of the new technology. Finally, we have to continuously monitor the integration process and seek feedback from employees to identify any issues or challenges that need to be addressed. We should be flexible and willing to adapt the integration plan based on the lessons learned throughout the process.

These things come to mind: 1. Easy to use for broad adoption. Lean is a culture/behavioral change effort, hence the SW should help the entire organization adopt, spread, and sustain the behaviors and culture. The SW should seamlessly guide people without lean background to successfully practice "lean" behaviors. 2. Easy to pilot and then scale: most want to start small, test, and later scale. 3. Make it seamless and easy to shift from pen, paper, physical solutions to virtual solutions. 4. Better to do a terrific job of solving a specific customer need than trying to be a Swiss army knife, do many things but only do them ok. 5. Integrate with other technology the customer is already using for ease of use across tools and platforms.

New technology support the automation (jidoka) to move to next level. Today, process automation and new technology are the drivers for operational strategies based on waste elimination.

I would first ensure that there is a bountiful number of use studies that showed practical application of the technology similar to what you would use it for, created differentiated outcomes. I would then ensure that foundational lean principles were used with and around the new technology.