{"id":4950,"date":"2022-07-20T12:07:54","date_gmt":"2022-07-20T05:07:54","guid":{"rendered":"https:\/\/suryacipta.com\/?p=4950"},"modified":"2023-05-30T12:56:28","modified_gmt":"2023-05-30T05:56:28","slug":"cost-efficiency-by-integration-of-lean-manufacturing-industry-4-0","status":"publish","type":"post","link":"https:\/\/suryacipta.com\/cn\/cost-efficiency-by-integration-of-lean-manufacturing-industry-4-0\/","title":{"rendered":"Cost Efficiency by Integration of Lean Production &#038; Industry 4.0"},"content":{"rendered":"<p>The integration of lean manufacturing or lean production and industry 4.0 helps with cost efficiency and increasing productivity within any manufacturing industry. Both concepts run in the same direction and thus have the capacity to bring out the best result.<\/p>\n<div id=\"ez-toc-container\" class=\"ez-toc-v2_0_83 counter-hierarchy ez-toc-counter ez-toc-grey ez-toc-container-direction\">\n<div class=\"ez-toc-title-container\">\n<p class=\"ez-toc-title\" style=\"cursor:inherit\">Table of Contents<\/p>\n<span class=\"ez-toc-title-toggle\"><a href=\"#\" class=\"ez-toc-pull-right ez-toc-btn ez-toc-btn-xs ez-toc-btn-default ez-toc-toggle\" aria-label=\"Toggle Table of Content\"><span class=\"ez-toc-js-icon-con\"><span class=\"\"><span class=\"eztoc-hide\" style=\"display:none;\">Toggle<\/span><span class=\"ez-toc-icon-toggle-span\"><svg style=\"fill: #999;color:#999\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" class=\"list-377408\" width=\"20px\" height=\"20px\" viewBox=\"0 0 24 24\" fill=\"none\"><path d=\"M6 6H4v2h2V6zm14 0H8v2h12V6zM4 11h2v2H4v-2zm16 0H8v2h12v-2zM4 16h2v2H4v-2zm16 0H8v2h12v-2z\" fill=\"currentColor\"><\/path><\/svg><svg style=\"fill: #999;color:#999\" class=\"arrow-unsorted-368013\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"10px\" height=\"10px\" viewBox=\"0 0 24 24\" version=\"1.2\" baseProfile=\"tiny\"><path d=\"M18.2 9.3l-6.2-6.3-6.2 6.3c-.2.2-.3.4-.3.7s.1.5.3.7c.2.2.4.3.7.3h11c.3 0 .5-.1.7-.3.2-.2.3-.5.3-.7s-.1-.5-.3-.7zM5.8 14.7l6.2 6.3 6.2-6.3c.2-.2.3-.5.3-.7s-.1-.5-.3-.7c-.2-.2-.4-.3-.7-.3h-11c-.3 0-.5.1-.7.3-.2.2-.3.5-.3.7s.1.5.3.7z\"\/><\/svg><\/span><\/span><\/span><\/a><\/span><\/div>\n<nav><ul class='ez-toc-list ez-toc-list-level-1 ' ><li class='ez-toc-page-1 ez-toc-heading-level-2'><a class=\"ez-toc-link ez-toc-heading-1\" href=\"https:\/\/suryacipta.com\/cn\/cost-efficiency-by-integration-of-lean-manufacturing-industry-4-0\/#Understanding_Lean_Production_and_Industry_40\" >Understanding Lean Production and Industry 4.0<\/a><ul class='ez-toc-list-level-3' ><li class='ez-toc-heading-level-3'><a class=\"ez-toc-link ez-toc-heading-2\" href=\"https:\/\/suryacipta.com\/cn\/cost-efficiency-by-integration-of-lean-manufacturing-industry-4-0\/#Technology_in_Industry_40_Used_in_Smart_Factory_for_Lean_Manufacturing\" >Technology in Industry 4.0 Used in Smart Factory for Lean Manufacturing<\/a><ul class='ez-toc-list-level-4' ><li class='ez-toc-heading-level-4'><a class=\"ez-toc-link ez-toc-heading-3\" href=\"https:\/\/suryacipta.com\/cn\/cost-efficiency-by-integration-of-lean-manufacturing-industry-4-0\/#Smart_sensors\" >Smart sensors<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-4'><a class=\"ez-toc-link ez-toc-heading-4\" href=\"https:\/\/suryacipta.com\/cn\/cost-efficiency-by-integration-of-lean-manufacturing-industry-4-0\/#Edge_computing\" >Edge computing<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-4'><a class=\"ez-toc-link ez-toc-heading-5\" href=\"https:\/\/suryacipta.com\/cn\/cost-efficiency-by-integration-of-lean-manufacturing-industry-4-0\/#Cyber-physical_system\" >Cyber-physical system<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-4'><a class=\"ez-toc-link ez-toc-heading-6\" href=\"https:\/\/suryacipta.com\/cn\/cost-efficiency-by-integration-of-lean-manufacturing-industry-4-0\/#Predictive_maintenance\" >Predictive maintenance<\/a><\/li><\/ul><\/li><li class='ez-toc-page-1 ez-toc-heading-level-3'><a class=\"ez-toc-link ez-toc-heading-7\" href=\"https:\/\/suryacipta.com\/cn\/cost-efficiency-by-integration-of-lean-manufacturing-industry-4-0\/#Collaboration_Between_Industry_40_and_Lean_Production\" >Collaboration Between Industry 4.0 and Lean Production<\/a><ul class='ez-toc-list-level-4' ><li class='ez-toc-heading-level-4'><a class=\"ez-toc-link ez-toc-heading-8\" href=\"https:\/\/suryacipta.com\/cn\/cost-efficiency-by-integration-of-lean-manufacturing-industry-4-0\/#Production_planning\" >Production planning<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-4'><a class=\"ez-toc-link ez-toc-heading-9\" href=\"https:\/\/suryacipta.com\/cn\/cost-efficiency-by-integration-of-lean-manufacturing-industry-4-0\/#Cost_reduction\" >Cost reduction<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-4'><a class=\"ez-toc-link ez-toc-heading-10\" href=\"https:\/\/suryacipta.com\/cn\/cost-efficiency-by-integration-of-lean-manufacturing-industry-4-0\/#Flexibility\" >Flexibility<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-4'><a class=\"ez-toc-link ez-toc-heading-11\" href=\"https:\/\/suryacipta.com\/cn\/cost-efficiency-by-integration-of-lean-manufacturing-industry-4-0\/#Productivity\" >Productivity<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-4'><a class=\"ez-toc-link ez-toc-heading-12\" href=\"https:\/\/suryacipta.com\/cn\/cost-efficiency-by-integration-of-lean-manufacturing-industry-4-0\/#Quality\" >Quality<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-4'><a class=\"ez-toc-link ez-toc-heading-13\" href=\"https:\/\/suryacipta.com\/cn\/cost-efficiency-by-integration-of-lean-manufacturing-industry-4-0\/#Safety\" >Safety<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-4'><a class=\"ez-toc-link ez-toc-heading-14\" href=\"https:\/\/suryacipta.com\/cn\/cost-efficiency-by-integration-of-lean-manufacturing-industry-4-0\/#Maintenance\" >Maintenance<\/a><\/li><li class='ez-toc-page-1 ez-toc-heading-level-4'><a class=\"ez-toc-link ez-toc-heading-15\" href=\"https:\/\/suryacipta.com\/cn\/cost-efficiency-by-integration-of-lean-manufacturing-industry-4-0\/#Data_collection\" >Data collection<\/a><\/li><\/ul><\/li><\/ul><\/li><\/ul><\/nav><\/div>\n<h2><span class=\"ez-toc-section\" id=\"Understanding_Lean_Production_and_Industry_40\"><\/span>Understanding Lean Production and Industry 4.0<span class=\"ez-toc-section-end\"><\/span><\/h2>\n<p>Lean system is a term coined in the fifties by <a href=\"https:\/\/www.toyota.com\/\" target=\"_blank\" rel=\"noopener\">Toyota<\/a>. The term refers to five standards: work standard, work balance, continuous improvement, just-in-time production, and root cause analysis. The main goal is to <a href=\"https:\/\/suryacipta.com\/the-benefits-of-manufacturing-execution-system-mes-for-enhance-operational-business\/\">improve production<\/a>, reduce waste, reduce delivery time, and cost-efficiency.<\/p>\n<p><a href=\"https:\/\/suryacipta.com\/smart-manufacturing-and-industry-4-0\/\">Industry 4.0<\/a> refers to the automation and digital transformation era, achieved by implementing various technologies such as the Internet of Things (IoT), <a href=\"https:\/\/suryacipta.com\/cloud-computing-strategy-to-reduce-operational-cost\/\">edge computing<\/a>, cyber-physical systems, and many more. The main goal is similar to the system; which includes supply chain optimization, reducing cost, improving productivity, and reducing defective products and waste. Industry 4.0 serves the purpose of making industrial practice more autonomous and efficient.<\/p>\n<p>Industry 4.0 supports lean manufacturing by saving money, time, energy, human resources, and material resources. It works by implementing several technologies at the same time.<\/p>\n<h2><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter wp-image-4955 size-large\" src=\"https:\/\/suryacipta.com\/wp-content\/uploads\/2022\/07\/Lean-Production-1024x684.png\" alt=\"Lean Production\" width=\"640\" height=\"428\" srcset=\"https:\/\/suryacipta.com\/wp-content\/uploads\/2022\/07\/Lean-Production-1024x684.png 1024w, https:\/\/suryacipta.com\/wp-content\/uploads\/2022\/07\/Lean-Production-300x200.png 300w, https:\/\/suryacipta.com\/wp-content\/uploads\/2022\/07\/Lean-Production-768x513.png 768w, https:\/\/suryacipta.com\/wp-content\/uploads\/2022\/07\/Lean-Production-1536x1025.png 1536w, https:\/\/suryacipta.com\/wp-content\/uploads\/2022\/07\/Lean-Production.png 2048w\" sizes=\"auto, (max-width: 640px) 100vw, 640px\" \/><\/h2>\n<h3><span class=\"ez-toc-section\" id=\"Technology_in_Industry_40_Used_in_Smart_Factory_for_Lean_Manufacturing\"><\/span>Technology in Industry 4.0 Used in Smart Factory for Lean Manufacturing<span class=\"ez-toc-section-end\"><\/span><\/h3>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"aligncenter wp-image-5521 size-full\" src=\"https:\/\/suryacipta.com\/wp-content\/uploads\/2023\/03\/cobots.jpg\" alt=\"\" width=\"553\" height=\"254\" srcset=\"https:\/\/suryacipta.com\/wp-content\/uploads\/2023\/03\/cobots.jpg 553w, https:\/\/suryacipta.com\/wp-content\/uploads\/2023\/03\/cobots-300x138.jpg 300w\" sizes=\"auto, (max-width: 553px) 100vw, 553px\" \/><\/p>\n<p>Multiple technologies of industry 4.0 are used in lean manufacturing system. Some of them are:<\/p>\n<ol>\n<li>\n<h4><span class=\"ez-toc-section\" id=\"Smart_sensors\"><\/span>Smart sensors<span class=\"ez-toc-section-end\"><\/span><\/h4>\n<p>Smart sensors are placed in different locations such as the shop floor plan. The sensor gathers data, machine utilization, part counts, and other raw data that are contextualized and allow the operator and management to take appropriate action.<\/li>\n<li>\n<h4><span class=\"ez-toc-section\" id=\"Edge_computing\"><\/span>Edge computing<span class=\"ez-toc-section-end\"><\/span><\/h4>\n<p>Edge computing in the system located inside the factory. It collects and analyzes data faster, thus allowing immediate action to be taken when needed. For example, if the data shows the possibility of a safety hazard, the machines can be stopped immediately.<\/li>\n<li>\n<h4><span class=\"ez-toc-section\" id=\"Cyber-physical_system\"><\/span>Cyber-physical system<span class=\"ez-toc-section-end\"><\/span><\/h4>\n<p>The system monitors the entire floor factory, where the data is used to guide automated decisions.<\/li>\n<li>\n<h4><span class=\"ez-toc-section\" id=\"Predictive_maintenance\"><\/span>Predictive maintenance<span class=\"ez-toc-section-end\"><\/span><\/h4>\n<p>Predictive maintenance relies on data collected from the sensors and cyber-physical systems, then analyzed to develop a maintenance plan. It means maintenance will be done to prevent possible issues happening, for example replacing parts before they lose their effectiveness.<\/li>\n<\/ol>\n<h3><span class=\"ez-toc-section\" id=\"Collaboration_Between_Industry_40_and_Lean_Production\"><\/span>Collaboration Between Industry 4.0 and Lean Production<span class=\"ez-toc-section-end\"><\/span><\/h3>\n<p><img loading=\"lazy\" decoding=\"async\" class=\"size-full wp-image-4335 aligncenter\" src=\"https:\/\/suryacipta.com\/wp-content\/uploads\/2022\/05\/Production-Management-Software.jpg\" alt=\"\" width=\"1200\" height=\"630\" srcset=\"https:\/\/suryacipta.com\/wp-content\/uploads\/2022\/05\/Production-Management-Software.jpg 1200w, https:\/\/suryacipta.com\/wp-content\/uploads\/2022\/05\/Production-Management-Software-300x158.jpg 300w, https:\/\/suryacipta.com\/wp-content\/uploads\/2022\/05\/Production-Management-Software-1024x538.jpg 1024w, https:\/\/suryacipta.com\/wp-content\/uploads\/2022\/05\/Production-Management-Software-768x403.jpg 768w\" sizes=\"auto, (max-width: 1200px) 100vw, 1200px\" \/><\/p>\n<p>Collaboration between the system and industry 4.0 works on the different aspects of the entire manufacturing system including:<\/p>\n<ol>\n<li>\n<h4><span class=\"ez-toc-section\" id=\"Production_planning\"><\/span>Production planning<span class=\"ez-toc-section-end\"><\/span><\/h4>\n<p>Lean manufacturing focuses on adapting to production changes to create a better plan of production. Industry 4.0 uses integrated data from various sources to create an ideal production plan.<\/li>\n<li>\n<h4><span class=\"ez-toc-section\" id=\"Cost_reduction\"><\/span>Cost reduction<span class=\"ez-toc-section-end\"><\/span><\/h4>\n<p>The system creates the best plan to reduce inventory cost production. Industry 4.0 analyze and sets a reminder for part replacement.<\/li>\n<li>\n<h4><span class=\"ez-toc-section\" id=\"Flexibility\"><\/span>Flexibility<span class=\"ez-toc-section-end\"><\/span><\/h4>\n<p>Lean manufacturing uses lean tools to enable multiple productions from one production line. Industry 4.0 identifies and then loads the program and tool automatically.<\/li>\n<li>\n<h4><span class=\"ez-toc-section\" id=\"Productivity\"><\/span>Productivity<span class=\"ez-toc-section-end\"><\/span><\/h4>\n<p>Lean manufacturing system focus on continuous improvement through the entire production process. Industry 4.0 use real-time data to identify root causes and measure improvement, to ensure faster production.<\/li>\n<li>\n<h4><span class=\"ez-toc-section\" id=\"Quality\"><\/span>Quality<span class=\"ez-toc-section-end\"><\/span><\/h4>\n<p>Lean manufacturing uses inspection tools to reduce product defects. Industry 4.0 support the inspection process using data-driven analytic.<\/li>\n<li>\n<h4><span class=\"ez-toc-section\" id=\"Safety\"><\/span>Safety<span class=\"ez-toc-section-end\"><\/span><\/h4>\n<p>The system uses a signal of any kind, such as warning signs, to improve safety. Industry 4.0 uses a sensor to alert worker when any safety hazard detected.<\/li>\n<li>\n<h4><span class=\"ez-toc-section\" id=\"Maintenance\"><\/span>Maintenance<span class=\"ez-toc-section-end\"><\/span><\/h4>\n<p>The system works on preventive maintenance based on the schedule, to reduce downtime due to machine error. Industry 4.0 focuses on predictive maintenance, where maintenance is done only when it was necessary.<\/li>\n<li>\n<h4><span class=\"ez-toc-section\" id=\"Data_collection\"><\/span>Data collection<span class=\"ez-toc-section-end\"><\/span><\/h4>\n<p>Lean manufcaturing systems gather customer data and uses it to improve product quality. Industry 4.0 uses a sensor to gather product performance data to match the specific needs of each customer.<\/li>\n<\/ol>\n<p>In conclusion, industry 4.0 boost lean production and does not go against each other, to achieve the same purpose of growing bigger and better.<\/p>\n<p>&nbsp;<\/p>\n","protected":false},"excerpt":{"rendered":"<p>The integration of lean manufacturing or lean production and industry 4.0 helps with cost efficiency and increasing productivity within any manufacturing industry. Both concepts run in the same direction and thus have the capacity to bring out the best result. Understanding Lean Production and Industry 4.0 Lean system is a term coined in the fifties [&hellip;]<\/p>\n","protected":false},"author":6,"featured_media":4951,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"inline_featured_image":false,"footnotes":""},"categories":[20],"tags":[],"class_list":["post-4950","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-blog-article"],"_links":{"self":[{"href":"https:\/\/suryacipta.com\/cn\/wp-json\/wp\/v2\/posts\/4950","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/suryacipta.com\/cn\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/suryacipta.com\/cn\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/suryacipta.com\/cn\/wp-json\/wp\/v2\/users\/6"}],"replies":[{"embeddable":true,"href":"https:\/\/suryacipta.com\/cn\/wp-json\/wp\/v2\/comments?post=4950"}],"version-history":[{"count":8,"href":"https:\/\/suryacipta.com\/cn\/wp-json\/wp\/v2\/posts\/4950\/revisions"}],"predecessor-version":[{"id":6007,"href":"https:\/\/suryacipta.com\/cn\/wp-json\/wp\/v2\/posts\/4950\/revisions\/6007"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/suryacipta.com\/cn\/wp-json\/wp\/v2\/media\/4951"}],"wp:attachment":[{"href":"https:\/\/suryacipta.com\/cn\/wp-json\/wp\/v2\/media?parent=4950"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/suryacipta.com\/cn\/wp-json\/wp\/v2\/categories?post=4950"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/suryacipta.com\/cn\/wp-json\/wp\/v2\/tags?post=4950"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}