In the production area of manufacturing, lean management is implemented through a combination of automation, increased efficiency and precise process control. The following four areas play a central role, particularly with regard to modern production technologies:
1. Automation: In areas with monotonous, repetitive tasks, automation is used to increase productivity and minimize errors caused by human interaction. Automation of production is particularly suitable for low product variance and stable production volumes. However, it also poses challenges: Machines need to be regularly maintained and repaired in the event of malfunctions, for example, which reduces availability. In addition, set-up requires specialized knowledge.
2. Overall equipment effectiveness (OEE): Overall equipment effectiveness is an important key figure for measuring the efficiency of machines and systems. It records the actual output in comparison to the maximum possible output and reveals losses in the areas of availability, performance and quality. By consistently optimizing the OEE, unproductive times are identified and reduced, resulting in better utilization of the production facilities.
3. Total productive maintenance (TPM): TPM focuses on preventive maintenance of machines in order to minimize downtimes and extend the service life of the systems. It actively integrates employees into the maintenance process in order to identify and rectify faults before they become major problems. This improves the availability and efficiency of production facilities.
4. Industry 4.0: The digitalization of production brings additional opportunities for optimization. Industry 4.0 links machines, systems and processes through the use of technologies such as sensors, big data and artificial intelligence. This allows real-time data to be used to monitor and improve production. A key success factor is that lean principles such as waste reduction serve as the basis for the introduction of Industry 4.0. This is the only way to fully exploit the technological potential.
Once again, an example from liquid filling with GREIF VELOX systems can be used to illustrate this.
Standardisation is achieved through automated capping mechanisms and integrated quality controls. These processes ensure the integrity of the end product and eliminate error-prone manual intervention. For example, the closure is automatically checked for each container, which prevents reworking or potential damage to the product.
Continuous improvement is supported by the use of real-time data and process monitoring. GREIF VELOX liquid filling systems continuously collect and analyse production data, identifying bottlenecks and optimising production in real time.