How Industry 4.0 Continues to Transform Lean manufacturing?

What Does Industry 4.0 Mean for Lean Manufacturing?

Over the last few decades, lean manufacturing has more focused on keeping a customer-centric approach and now Lean 4.0 technologies have made it possible for manufacturers to have a clearer view of waste reduction. Industry 4.0 supports lean manufacturers to save time, money, and energy, as well as material resources, and human resources, specifically when various Industry 4.0 technologies are placed simultaneously.

The initial concept of lean manufacturing is actually quite simple that relentlessly works on minimizing waste from the manufacturing process.

BCG reports that organizations that integrate lean and industry 4.0 can achieve near about 40% cost reduction. 

Though, unlike Industry 4.0, which depends on modern technology to resolve the contemporary problems that industries face, Lean is a technology adversary that focused on people, processes and a culture of continuous improvement but has the same objective of improved productivity and flexibility.

At KNEO we take an integrated perspective for Industry 4.0 implementation.

In Industry 4.0  there are three primary ways to gather data

Data acquisition & Data Processing 

Machine to Machine Communication 

Human Machine Interface 

Data acquisition & Data Processing 

All shop-floor data is gathered using suitable smart devices, sensors, etc. The collected data is stored in big data platforms for further analytics. The analytics helps to identify unstable process parameters, and quality concerns if defined tolerances are exceeded.  KPI’s and OEE can be acquired automatically from this analysis and predictive maintenance is also possible. 

M2M communication 

The M2M concept integrates the approach of vertical and horizontal integration. In vertical integration, the data from machines is connected to the MES system and ERP system. Gapless vertical flow assures one-piece data flow without manual changeovers.  In horizontal integration, all machines are connected to each other. If there is a capacity hampering production the connected machines will notify the available capacities on the network. 

Human to Machine Interface 

Human-to-machine data collection is basically derived from operators through a digital interface. The Cyber-Physical System can gather data through traditional data entry, methods such as typing into a computer or selecting options on a tablet. Common UI/UX design principles make it simpler for people to embrace new HMI technologies.

Lean manufacturing has several modules:


OEE considers various losses (Stop Time Loss, Speed Loss, and Quality Loss), resulting in a measure of simply productive manufacturing time.

In general, it is calculated as:

OEE = Availability × Performance × Quality

• Availability (e.g., downtime)

• Performance (e.g., slow cycles)

• Quality (e.g., product rejects)

How does Overall Equipment Effectiveness help?

It gives a baseline and a means to track progress in removing waste from a manufacturing process.

How MAPP helps.

Ø With MAPP module we enable automatic data collection which is the most efficient and reliable means of data collection.

Ø Automatic calculation of OEE saves time and efforts.

Bottleneck Analysis   

Recognize which part of the manufacturing process restricts the overall throughput and optimize the performance of that part of the process. 

A successful implementation will have the following advantages:

• Improved profit 

• Increased capacity (optimizing the constraint allows more products to be manufactured)

• Minimized lead times (optimizing the constraint results in even and faster product flow)

• Minimized inventory (reducing bottlenecks means there will be fewer excess work-in-progress items)

Ø We focused on Man, Machine, Material and method-related issues for analysis..

Ø Corrective action can be taken on the above data and the effectiveness of actions taken can be analyzed in MAPP

KPIs (Key Performance Indicators)

Metrics are outlined to track and prompt progress toward the crucial goals of the company. Strongly developed KPIs can be very powerful drivers of behavior – so it is essential to carefully select KPIs that will drive desired behavior.

How do KPIs help?

The best manufacturing KPIs:

Are lined up with top-level strategic goals (thus helping to attain those goals)

Are efficient at revealing and evaluating waste (OEE is a good example)

Are easily determined by plant floor employees (so they can drive results)


Ø Customised Dashboard feature of MAPP enables monitoring of KPI’s from several locations on PC or Mobile devices.

For e.g  10% production loss can be specified as KPI in the traditional way but MAPP enables customers to search for the exact reason behind the 10% loss. Once reasons are identified, corrective actions can be taken.  

Root Cause Analysis

What is Root Cause Analysis?

A problem-solving concept that concentrates on solving the key concerns instead of applying rapid fixes that only treat instant signs of the problem. By asking why near about five times though, you can drill down more easily to the root of the breaches. 

How does Root Cause Analysis help?

It helps to recognize what, how, and why an event occurred so that you can take the necessary corrective actions to ensure that it does not repeat. 

How MAPP helps.

Ø Interrogation of the data gathered from across sources in different ways helps in finding the root cause.

Ø Smart tag programming technique to analyze conditions for root cause analysis.

Ø Interdependencies in a line manufacturing can be seen on timelines to identify the root cause .

Poka-Yoke (Error Proofing Solution)

What is Poka-Yoke?

Build error detection and prevention solutions into production processes with the aim of achieving no defects.

How does Error Proofing Solution help?

It is hard (and expensive) to find all faults through inspection, and correcting those defects generally becomes more expensive at each stage of production.

How MAPP helps.

Ø Master data Configuration on the server empowers comparison of actions taken at different stages and any deviation results in the stoppage of the machine..

Ø Camera systems with ML abilities that are combined with automation prevent wrong parts from proceeding.

Ø Integrating traditionally stand-alone gauges into the digitization process empowers stoppage of faults at an early stage.

Six Big Losses

Six categories of productivity loss that are faced by many manufacturing industries are:

Setup/Adjustments, Small Stops, Minimized Speed, Start-up Rejects, Production Rejects

How do Six Big Losses help?

They give a framework for striking the most common causes of waste in manufacturing.

Ø Identifying the trending faults (defects) is a default feature of MAPP Platform

Ø User configurable menu allows faults to be classified into categories and six big losses can be easily identified

Visual Factory & Andon

Visual indicators, displays, as well as controls, are utilized throughout manufacturing plants to increase the communication of data.

What is Andon?

The visual feedback system for the plant floor specifies the production status, alerts when assistance is required and enables operators to terminate the production process.

Ø Data from shop floor can be displayed on large displays using innovative hardware solutions.

Ø Smart Digital Assistant displays gives visual feedback to operators , indicates production status, enables operator to stop production process

Value Stream Mapping

What is Value Stream Mapping?

VSM is observed as one of the essential Lean technical solutions to efficiency improvement. It reveals waste in the current processes and gives a roadmap for improvement through the future state. However, it also shows the current and future state of processes in a way that describes opportunities for improvement

Ø Webscada module incorporated in the MAPP suite gives visual map of the production process and paves path for value stream analysis

Just-In-Time (JIT)

It is recognized as one of the pillars of Lean Manufacturing. JIT depends on precise and timely data of inventory as a necessity for its successful reduction of safety stocks and huge buffers.

The digitalization of supply chains can enhance this as transparency via better tracking and precise data on the level of inventories and their location becomes available

Ø For JIT to succeed the whole process from suppliers, ERP and shop floor require to be connected. Generally connecting each stage of the shop floor is a big challenge. MAPP is designed for OT and IT integration and assists the seamless flow of data required for JIT

  • Now, with industry 4.0 enhancers like IT-OT integration, IoT and advanced data analysis, industries are getting an explicit understanding of the whole value chain to notify lean improvement opportunities and ultimately get a competitive benefit.
  • To learn more about incorporating the Kneo Automation MAPP Platform on your shop floor, get in touch.

Leave a Reply

Your email address will not be published. Required fields are marked *