EURO 2025 Leeds
Abstract Submission

1612. An implementation framework for digital lean production and case studies

Invited abstract in session TC-12: Application of scheduling models, stream Scheduling and Project Management.

Tuesday, 12:30-14:00
Room: Clarendon SR 1.02

Authors (first author is the speaker)

1. Taho Yang
Institute of Manufacturing Information and Systems, National Cheng Kung University

Abstract

Lean and Industrie 4.0 (or smart manufacturing) are two approaches, but they have one common goal: the pursuit of zero waste. The lean approach can be systematically connected with the new opportunities of digitalization and Industrie 4.0. We called it Lean 4.0—reaching the next level of excellence through digitalization. There is a significant amount of literature on either Lean or smart manufacturing. However, practical applications for Lean 4.0 are rare. This paper proposed a Lean 4.0 implementation framework—JIT-Jidoka Cycle (JJC). It is based on the two pillars of the TPS house—JIT and Jidoka, and a continuous improvement cycle. When automation technologies are adopted, Toyota-style factories tend to be conservative economically and technologically. It is a so-called low-cost or semi-automatic system with just enough functions. JJC adopts the same philosophy when adopting digitalization technology. We may coin this concept as a Low-cost Smart System (LCSS), which became the implementation framework of Lean 4.0.
The proposed JJC approach has been applied to various applications with promising results. It has been used in die mold development. It resulted in an 80% decrease in development lead time. The application to textile manufacturing increased its on-time delivery rate by 33%. The effectiveness of the proposed JJC approach is justified through a series of practical applications.

Keywords

Status: accepted

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