Here's how you can mitigate the risks of over-reliance on new technology in Lean Manufacturing.

In my experience, it’s crucial to thoroughly assess the risks before implementing new technology in Lean Manufacturing. Jumping into automation without considering potential drawbacks, such as system malfunctions or overdependence, can disrupt production. Conducting risk assessments upfront helps identify areas where technology might fail or need support, allowing for better contingency planning.

To mitigate the risks of over-reliance on new technology in Lean Manufacturing, a structured approach to risk assessment and management is essential. Here we should start by identifying potential risks such as system failures, cybersecurity threats, and process disruptions, and assess their likelihood and impact. We may need to use a risk matrix to prioritize high-impact risks and develop mitigation plans. We should continuously monitor risks through regular audits, using cybersecurity tools to detect vulnerabilities in the system. Effective risk communication ensures all stakeholders are aware of both real and perceived risks.

Mitigating the risks of over-reliance on new technology in Lean Manufacturing requires a balanced approach. We can adopt a few steps as follows 1. Thorough Evaluation of Technology Before implementing 2. Gradual Implementation of new technologies 3. Training and Skill Development 4. Maintain Flexibility 5. Focus on Problem Solving 6. Cross-functional Teams: Form cross-functional teams to evaluate how new technology integrates with existing processes. Their diverse perspectives can help identify potential pitfalls early and develop solutions. 7. Monitor Performance and Adjust 8. Backup and Contingency Planning

Para mitigar os riscos de dependência excessiva de novas tecnologias em Lean Manufacturing, é importante avaliar cuidadosamente os impactos antes de uma implementa??o completa. Novas tecnologias podem apresentar desempenho instável ou n?o se adequar perfeitamente ao processo produtivo existente, portanto, um bom come?o é testar em pequena escala, em ambientes controlados, antes de expandir para toda a opera??o. Além disso, é essencial garantir que a equipe tenha treinamento adequado para operar e gerenciar essas tecnologias, evitando dependência exclusiva de sistemas automáticos.

The first step is to assess the potential risks upfront. Look at how critical the technology is to your processes and identify failure points—what happens if it goes down? Always have a contingency plan in place and make sure your team is well-trained in manual processes. Lean is about flexibility, so while technology can enhance efficiency, don’t let it become a crutch that makes you vulnerable when things go wrong.

I’ve seen that investing in employee training before new technology is fully integrated is key. When we introduced a new system at Jabil EMS, training sessions ensured the team understood both the technology and how to respond to issues. Well-trained employees are more adaptable and less reliant on the technology itself, reducing risks in case of failure.

Employee training is a powerful tool to combat resistance. When you or a lean expert educate your employees, especially direct ones, emphasize examples from practice. Let them understand that they will work more comfortably and with less stress in a 5S environment. Let them understand that LM and new technologies are not "enemies". Real-time data will only increase the efficiency of the lean system. However, if you have real-time data but are not using a LM, your organization may not be able to achieve optimal results. For example, let's assume that digital technology provides you with data on the exact time duration of each phase during a production changeover. This data will not be optimally used until you use a tool called SMED.

O treinamento de funcionários é um dos pilares fundamentais para garantir o sucesso de qualquer metodologia de melhoria contínua, incluindo Lean Manufacturing. Investir no desenvolvimento das pessoas significa capacitá-las para identificar problemas, propor solu??es e aplicar as ferramentas corretas de maneira eficaz. O foco deve ser em habilidades práticas que possam ser aplicadas diretamente no ch?o de fábrica, sempre integrando teoria com prática.

Make sure your team understands both the technology and the fundamentals of the process, so they’re not dependent on the tools alone. Regular cross-training and hands-on practice with manual systems will keep your team adaptable and prepared for any breakdowns. The goal is to ensure that technology enhances your Lean efforts, but your workforce remains the true driver of success.

Ensure employees are well-trained on new technology to reduce reliance on a few key operators and prevent disruptions. Training helps teams use the technology efficiently while maintaining manual skills in case of system failures, ensuring that operations can continue smoothly.

A mudan?a incremental é uma abordagem essencial em processos de melhoria contínua, especialmente no contexto do Lean Manufacturing. Em vez de buscar grandes transforma??es de uma só vez, o foco está em pequenas melhorias, realizadas de forma contínua e sistemática. Essas mudan?as, apesar de parecerem pequenas individualmente, acumulam-se ao longo do tempo, gerando resultados significativos. Ao adotar a mudan?a incremental, é possível minimizar os riscos, já que cada altera??o é avaliada e ajustada rapidamente. Isso também facilita a aceita??o por parte dos colaboradores, que se adaptam gradualmente às melhorias, sem a resistência que muitas vezes surge em processos de mudan?a radical.

Rather than making large, sudden changes, I’ve found that incremental implementation works best. Starting small allows us to test the technology, gather data, and adjust before rolling it out fully. This reduces the risk of widespread disruption and gives teams time to adapt without overwhelming them.

Don’t rush to implement everything at once—test new systems in small steps to ensure they’re delivering value without disrupting your processes. This approach allows you to fine-tune the technology and adapt to any challenges that come up along the way. Lean thrives on continuous improvement, and incremental changes help you stay flexible while reducing the risks of full-scale failures.

To mitigate the risks of over-reliance on new technology in Lean Manufacturing, embrace incremental change. Instead of implementing large-scale technology shifts, introduce new tools and processes gradually. Start with pilot programs to test their effectiveness and gather feedback from users. This approach allows you to identify potential issues early and make necessary adjustments without disrupting operations. Encourage a culture of continuous improvement, where employees can voice concerns and suggest enhancements. By integrating technology step-by-step, you can ensure that it complements existing processes and empowers your workforce, ultimately leading to sustainable improvements.

Introduce technology incrementally rather than all at once to avoid overwhelming employees and creating process bottlenecks. Start with smaller, manageable projects that allow you to gauge the impact of the technology and make adjustments before rolling it out fully.

To mitigate the risks of over-reliance on new technology in Lean Manufacturing, proactive strategies are key. We should start by conducting thorough risk assessments to identify potential challenges like system failures or cybersecurity threats. We must ensure employees are properly trained to use the technology, which reduces errors. Implement changes gradually, allowing time to adjust and address issues. Balance automation with human oversight to prevent critical functions from being fully dependent on technology. Finally, continuously apply Lean principles to improve processes, reduce waste and maintain flexibility. These approaches help manufacturers manage technology risks while maintaining efficiency and minimizing disruptions

To mitigate the risks of over-reliance on new technology in Lean Manufacturing, it is critical to regularly analyze its impact. Establish key performance indicators (KPIs) to assess the technology's impact on productivity, quality, and employee engagement. Regularly monitor these metrics to look for any undesirable trends or unforeseen repercussions. Solicit feedback from team members who use the technology to acquire insight into its usability and efficacy. This constant review enables appropriate modifications and ensures that technology benefits, rather than inhibits, your Lean projects, creating a balanced approach to innovation.

Track key performance metrics to see how the technology is affecting productivity, quality, and overall process flow. Regular reviews will help you catch any issues early and adjust before they become bigger problems. Keeping a close eye on the data ensures the technology supports your Lean goals without causing disruptions.

Continuously monitor the impact of the technology on productivity, quality, and overall workflow. Regular evaluations help identify if the technology is adding value or if over-reliance is causing new inefficiencies or quality issues.

It’s essential to balance automation with human oversight. While automation can drive efficiency, ensure your team stays engaged and involved in the process. Use technology to enhance decision-making, not replace it. A well-balanced approach ensures you get the best of both worlds—technology that boosts performance and people who can adapt and problem-solve when the unexpected happens.

Design processes to be adaptable so that if a technology becomes obsolete or fails, the process can still operate efficiently. This could involve modular or hybrid systems where new and old technologies work in tandem. By using these strategies, companies can leverage the benefits of new technology in Lean Manufacturing without becoming overly dependent on it.

Over-automation can lead to unintended consequences, such as reduced flexibility or dependency on systems. I've learned that balancing automation with human oversight is critical. In cases where technology falters, having skilled employees who can step in ensures smooth operations and maintains lean efficiency

Strike a balance between automation and human oversight. While automation can streamline processes, human intervention is often needed for quality control, troubleshooting, and continuous improvement. Avoid automating tasks that require critical thinking or adaptability.

I would integrate real-time data analytics to continuously monitor the performance of new technologies, ensuring immediate response to inefficiencies. In a sustainable agriculture project, we deployed IoT devices to track soil moisture levels for irrigation. Through continuous data analysis, we identified patterns where the system over-irrigated during certain weather conditions. We adjusted the system algorithm in response, improving water usage efficiency by 15%. This continuous feedback loop allowed us to maintain control over the technology’s performance while reinforcing lean principles of waste reduction.

Uma coisa que eu achei útil para mitigar os riscos de dependência excessiva de novas tecnologias em Lean Manufacturing é focar na melhoria contínua através da capacita??o da equipe. Ao investir em treinamentos regulares, as pessoas se tornam mais aut?nomas e capazes de identificar problemas antes que se tornem críticos. Além disso, promover uma cultura de feedback e colabora??o ajuda a garantir que as tecnologias sejam vistas como ferramentas complementares, e n?o como solu??es únicas. Implementar pequenos ciclos de teste para novas tecnologias também permite avaliar seu impacto real e ajustar processos antes de uma ado??o mais ampla. Isso equilibra inova??o e prudência, preservando os princípios Lean.

I believe that using the critical thinking to create new solutions to a problem is essencial to try to reduce the costs of buying new technologies. Connect this to controlled experiments with tools as DOE and COV, you can find the best parameters to your current machines without buying a new one for example. And, of course, be sure your machines are always linked with best practices of autonomous and professional maintenance.

After implementing new technology, continuous improvement must remain a priority. At Jabil, we used feedback loops to ensure that both the technology and processes were optimized over time. By continually refining and improving the technology’s role within lean principles, we could adapt to changing needs while minimizing risks.

Technology should be a tool that evolves with your processes, not a one-time fix. Regularly assess its performance, make adjustments, and keep finding ways to improve both the tech and how it integrates with your team’s workflow. Lean is all about ongoing refinement, and applying that to your tech strategy keeps you flexible and resilient.