Lean Smart Manufacturing 280
This class introduces the basic concepts and technologies of lean smart manufacturing. It summarizes several key capabilities and benefits of smart technology, including improved data collection, analysis, and accessibility, as well as optimization with artificial intelligence. Smart technology can be applied to traditional lean strategies such as pull systems, continuous product flow, and error prevention.
After taking this class, users will understand how smart technologies can be applied to lean manufacturing initiatives in order to increase efficiency and reduce waste. This knowledge is important because lean smart manufacturing is becoming increasingly common in many industries.
Number of Lessons 11
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- Introduction to Lean Smart Manufacturing
- Data Collection for Lean Smart Manufacturing
- Key Performance Indicators
- Data Visualization
- Artificial Intelligence
- Review: Smart Technology Capabilities
- Product Flow and Scheduling Applications
- Inventory and Pull System Applications
- Error Detection and Prevention Applications
- Employee Safety and Training Applications
- Final Review
- Describe the basic technologies of smart manufacturing.
- Describe data collection for lean smart manufacturing.
- Describe how smart manufacturing improves tracking of KPIs.
- Describe common data visualization tools for lean smart manufacturing.
- Describe how artificial intelligence contributes to lean smart manufacturing.
- Describe product flow and scheduling applications of smart technology.
- Describe inventory and pull systems applications of smart technology.
- Describe error detection and prevention applications of smart technology.
- Describe employee safety and training applications of smart technology.
A data visualization tool used to organize different data or ideas into categories. Affinity diagrams are sometimes used in brainstorming.
Artificial intelligence. A computer program with algorithms that function as behavioral rules, allowing a machine or computer to imitate intelligent human behavior. AI is able to discern and learn from its experiences in order to make optimized decisions during operation or for subsequent processes.
A visual management system that indicates the status of operations in an area and signals when an abnormality occurs. Andon often uses lights as signals.
AI. A computer program with algorithms that function as behavioral rules, allowing a machine or computer to imitate intelligent human behavior. Artificial intelligence is able to discern and learn from its experiences in order to make optimized decisions during operation or for subsequent processes.
AR. A technology that superimposes a computer-generated image over a view of the real world. Augmented reality may be used with smart safety goggles to visually alert the wearer to potential hazards.
Self-governing. Autonomous systems can be programmed to make decisions without human interaction.
A geometric pattern used to identify objects. A bar code is read by an optical scanner.
The process of switching a machine from one part setup to another. Changeover can be performed faster when operators receive instructions via mobile or wearable devices.
The occasional unwanted vibration between components, such as a cutting tool and a workpiece. Chatter decreases machining productivity, negatively impacts surface quality, and increases tool wear.
A graph used in statistical process control to show trends in data over time. Control charts show the upper and lower limits within which a process can operate and still be in control.
A moving strip of material that carries parts or other components from one area of a manufacturing facility to another. Conveyor belts are commonly used to transport parts from production to packaging.
cost of poor quality
COPQ. The expenses associated with products or services that lack quality. The cost of poor quality is caused by scrap, reinspected parts, product returns, and excess inspection.
The actual time it takes to perform a task and move onto the next step. One of the major goals of lean is to match cycle time to the customer's requirements.
A screen that summarizes important information and sometimes allows users to input commands. Dashboards, also called visual management boards, are used in lean smart manufacturing to display KPIs and status information about manufacturing processes.
Computer storage that holds data and is searchable. A database both stores and organizes information.
digital andon board
A type of dashboard that visually displays the status of many operations at once. Digital andon boards allow users to monitor machine operations via a computer or mobile device.
A virtual representation of a physical asset or part. Digital twins are used to track a part or asset throughout a process or entire lifecycle.
A period of time when production stops. Downtime is often caused by mechanical failures or maintenance needs.
A compact mobile robot that can be guided by programming or by a remote control. Drones can fly, swim, or sometimes both.
The rate at which the cutting tool and the workpiece move in relation to one another. Feed rate typically measures linear movement.
The lean practice of evening out the type and quantity of products made over a fixed period of time. Heijunka enables production to efficiently meet customer demands.
A failure or flaw in process that occurs as a result of an operator mistake due to factors such as being tired, lacking fine motor skills, or losing concentration. Human error is common in traditional, paper-based data collection systems.
Industrial Internet of Things. A network of physical devices used in manufacturing that contain computing systems that allow them to send and receive data. The IIoT allows devices to exchange data and automate processes without any human intervention.
Industrial Internet of Things
IIoT. A network of physical devices used in manufacturing that contain computing systems that allow them to send and receive data. The Industrial Internet of Things allows devices to exchange data and automate processes without any human intervention.
IT. A device that creates, processes, or stores electronic data. Common information technology devices include computers, tablets, and smartphones.
A safeguarding device that prevents a machine from operating when it is out of position or when a different operation is taking place. Interlocks help to prevent injury during operation.
Quantities of raw material, in-process parts, or completed, manufactured products that are held in storage. Excess inventory is considered waste in lean manufacturing.
JIT. A lean approach to production in which materials and products are ready precisely when they are needed. Just-in-time production reduces or eliminates inventory and in-process parts.
An inventory control system that signals when more material is needed. Traditional kanban uses visual signals like cards, while digital kanban uses bar codes or smart sensors.
key performance indicators
KPIs. A measurable value that demonstrates an organization's effectiveness in achieving important objectives. Key performance indicators for lean manufacturing may include cycle time or surplus inventory.
Key performance indicators. A measurable value that demonstrates an organization's effectiveness in achieving important objectives. KPIs for lean manufacturing may include cycle time or surplus inventory.
A device that uses a controlled beam of light to measure an object's geometric shape. Laser scanners collect large amounts of surface data quickly.
A machine tool commonly used to create cylindrical forms. A lathe holds a cylindrical workpiece on one or both ends while the cutting tool is gradually passed along the surface of the rotating part.
An approach to manufacturing that seeks to reduce waste in all its forms, increase flexibility, and improve quality. Lean manufacturing can be enhanced with the capabilities of smart technology.
A handheld, portable computer that can connect to the internet. Common mobile devices include smartphones and tablets.
A group of hardware devices connected by cables or by wireless methods. A network allows multiple devices to communicate and share information.
OT. A device that detects or causes changes in the physical environment. Operational technology devices include sensors and programmable logic controllers.
A method of inspection that uses sight, light, and magnification to examine the features of a part. Automated optical inspection devices such as laser scanners or specialized cameras reduce the chances of human error.
A bar graph used to identify the causes of problems that occur most frequently by distinguishing a problem's major factors from its minor factors. Pareto charts often demonstrate the Pareto principle, which states that, for most events, approximately 80% of the effects result from 20% of the causes.
Any tool or mechanism that prevents an employee from performing an action incorrectly. Poka-yoke might include devices such as warning signals, mechanisms that automatically shut down incorrectly operated machines, or tools designed to only fit in the correct storage boxes.
A maintenance approach that involves collecting data in order to anticipate and correct potential issues before they arise. A predictive maintenance approach involves performing maintenance before failures occur to prevent unscheduled downtime and reduce the labor, cost, and time needed for repairs.
A safety device that contains sensors to detect people or objects near hazardous areas of a machine. Presence-sensing devices include pressure-sensitive mats and light curtains.
A process flow chart that uses symbols and arrows to show the flow of the manufacturing process. Process maps are less complex than value stream maps.
programmable logic controllers
PLCs. A processor-driven device that uses logic-based software to provide electrical control to machines and processes. Programmable logic controllers are a type of operational technology.
A material management system in which materials and parts are not delivered to the next stage of a process until they are needed. Pull systems help reduce inventory.
An automated message that is sent to a mobile device. Push notifications can be used to send warnings, updates, and instructions directly to employees.
Describing a characteristic. Qualitative data is subjective information that usually cannot be measured in numbers.
A system of managing quality by regulating the quality of materials, assembly processes, products, and components. Quality assurance is a proactive approach to preventing errors.
Measuring an amount or number. Quantitative data typically includes anything that can be counted or measured numerically.
A type of electromagnetic wave that is longer than infrared light. Radio signals communicate data in RFID.
RFID. A technology that uses electromagnetic fields to automatically identify and track tags attached to objects. Radio-frequency identification tags consist of a tiny radio transponder, radio receiver, and radio transmitter.
The near-instantaneous interval of time that computers require to process data. Real time is virtually the same as actual time because computers process data almost immediately.
Radio-frequency identification. A technology that uses electromagnetic fields to automatically identify and track tags attached to objects. RFID tags consist of a tiny radio transponder, radio receiver, and radio transmitter.
A machine that can be programmed to perform a variety of complicated, repetitive tasks. Robots are used to automate manufacturing processes.
root cause analysis
A study undertaken to find the original or underlying cause of a problem. Root cause analysis involves collecting and analyzing data to determine the true cause of a problem.
A type of tight-fitting eye protection that completely covers the eyes, sockets, and surrounding facial area. Safety goggles offer protection from impact, dust, chips, splashes, and sometimes ultraviolet light.
Discarded. Scrapped parts increase overall production costs because they waste time and material.
A device that detects the presence or absence of an object, or certain properties of an object, and provides feedback. Sensors send feedback in the form of signals, which can be measured and recorded.
The process of preparing for a machining operation. Setup includes preparing machines as well as collecting paperwork, tools, and materials.
A computerized re-creation of a physical space and activity. Simulations are used to duplicate real-world situations in order to evaluate behavior under real conditions.
Capable of sending and receiving data without human intervention. Smart technology generally requires internet connectivity to enable data processing.
Technologically integrated manufacturing that creates and uses data in real time to address the needs of the factory, supplier, and customer. Smart manufacturing is an advancement of traditional manufacturing automation.
A device equipped with software that can detect physical inputs, process them as data, and output digital signals. Smart sensors are more advanced than normal digital sensors since they process data internally rather than sending digital signals to an external system to be processed.
A flat, rectangular handheld computer that is usually controlled by a touchscreen. Tablets are mobile devices that allow users to access information from any location.
A general direction in which something is developing. Trends indicate changes in data over time.
value stream maps
VSMs. A sophisticated flow chart that uses symbols, metrics, and arrows to help visualize processes and track performance. Value stream maps help determine which steps of a process add value and which do not.
Any deviation from what is normal and expected. In manufacturing, variation can cause or indicate errors.
VR. A computer-generated simulation of a real word image or environment that a user can interact with. Virtual reality is helpful for many types of employee training.
visual management boards
A screen that summarizes important information and sometimes allows users to input commands. Visual management boards, also called dashboards, are used in lean smart manufacturing to display KPIs and status information about manufacturing processes.
A device with a computer screen that is worn over user's eyes and displays a virtual environment. VR headsets are connected to handheld controllers and detect the user's motions, allowing the user to interact with a virtual environment.
Value stream maps. A sophisticated flow chart that uses symbols, metrics, and arrows to help visualize processes and track performance. VSMs help determine which steps of a process add value and which do not.
Any element of the manufacturing process that does not add value to a product. The goal of lean manufacturing is to eliminate waste.
A category of smart devices that people can wear on the body. Wearable technology can track, transmit, and display data.
An arrangement of machines, tooling, materials, and operators designed to perform all the tasks needed to produce a part in sequence. Work cells encourage smooth product flows and use space efficiently.