MDM Company June 1, 2021

The integration of industry4.0 in lean

manufacturing
MDM Company June 1, 2021

1 L’Integration d’industrie 4.0 et le lean 2 Production process evaluation

manufacturing

3 Etude de cas 4 Conclusion

MDM Company June 1, 2021

Introduction
lean manufacturing and Industry 4.0, two
key paradigms shaping the future of
manufacturing. As technology continues to
revolutionize the way we produce goods
and services, it is essential for companies to
embrace lean principles and Industry 4.0
technologies to stay competitive, efficient,
and innovative.
In this presentation, we will delve into:
• Dd
• Dd
• D
MDM Company June 1, 2021

What is lean manufacturing and how does it differ

from traditional manufacturing methods?

Are you ready?

 LEAN MANUFACTURING TRADITIONAL MANUFACTURING

It’s a systematic approach to involve large inventories,

production that focuses on batch production, and excess
eliminating waste, improving resources.
efficiency, and continuously
optimizing processes.

Action 1
aims to streamline
operations and deliver
value to customers By implementing lean principles such
with minimal waste. as identifying and eliminating
Exemple: inefficiencies, empowering employees
Imagine a kitchen where you are preparing a meal. In to make improvements, and
traditional manufacturing, you might buy all the focusing on customer value,
ingredients in bulk, prepare a large batch of food, and companies can achieve greater
store leftovers in the fridge. This approach can lead to productivity, quality, and flexibility
waste, as some ingredients may spoil or go unused. In in their operations. This lean
contrast, lean manufacturing is like cooking a meal just in mindset not only helps companies
time, using only the necessary ingredients and tools to reduce costs and lead times but
minimize waste and ensure freshness. also fosters a culture of continuous
improvement and innovation."
MDM Company June 1, 2021

How can lean principles such as waste reduction,

continuous improvement, and just-in-time
production benefit manufacturing processes?
Are you ready?
1.Waste Reduction: By identifying and eliminating waste, companies
can operate more efficiently, save costs, and deliver products faster to
customers.
2.Continuous Improvement: In manufacturing, this means constantly
looking for ways to make processes better, faster, and more effective.
By encouraging employees to suggest improvements and implement
changes, companies can stay ahead of the competition and adapt to
evolving market needs.
3.Just-in-Time Production This approach ensures that
products are made only when needed, reducing excess
inventory and storage costs. By producing goods in
response to customer demand, companies can improve cash
flow, minimize waste, and deliver products more efficiently.
MDM Company June 1, 2021

What are the key technologies and concepts associated with Industry 4.0, and how are
they transforming the manufacturing industry?
1.Internet of Things (IoT): In manufacturing, IoT enables machines, sensors, and
systems to communicate and share data in real-time, leading to increased automation,
predictive maintenance, and improved decision-making.

2. Artificial Intelligence (AI): AI algorithms can optimize production processes, detect

anomalies, and enhance quality control, leading to greater efficiency and productivity .

3. Big Data Analytics: In manufacturing, analyzing large volumes of data generated by

machines and systems can provide valuable insights for process optimization, demand
forecasting, and resource allocation.

4. Additive Manufacturing (3D Printing): In manufacturing, 3D printing technology

allows for rapid prototyping, customization, and on-demand production of complex
parts, reducing lead times and costs.

5. Cyber-Physical Systems: By integrating sensors, actuators, and control systems with

digital technologies, manufacturing processes become more interconnected,
autonomous, and responsive to changing conditions.
MDM Company June 1, 2021

How can companies integrate lean manufacturing

with Industry 4.0 technologies to improve
operational efficiency and competitiveness?
Are you ready?
1.Streamlined Processes: Lean manufacturing focuses on eliminating waste and optimizing processes, while Industry 4.0
technologies such as IoT and AI provide real-time data and insights for decision-making. By combining lean principles with
smart technologies, companies can streamline operations, reduce downtime, and improve overall efficiency.
2. Predictive Maintenance: Lean manufacturing emphasizes preventive measures to avoid breakdowns and
delays, while Industry 4.0 technologies enable predictive maintenance through sensors and data analytics. By
leveraging predictive maintenance tools, companies can anticipate equipment failures, schedule maintenance
proactively, and minimize production disruptions.
1.Data-Driven Decision-Making: Lean manufacturing encourages data-driven decision-making to drive continuous
improvement, while Industry 4.0 technologies offer advanced analytics and visualization tools. By integrating lean
practices with big data analytics, companies can gain deeper insights into their operations, identify optimization
opportunities, and make informed decisions to enhance competitiveness.
4. Agile Manufacturing: Lean manufacturing promotes flexibility and responsiveness to customer demands, while
Industry 4.0 technologies support agile manufacturing through automation and customization capabilities. By
adopting agile manufacturing strategies enabled by Industry 4.0 technologies, companies can adapt quickly to market
changes, customize products efficiently, and stay ahead of competitors .
5. Employee Empowerment: Lean manufacturing emphasizes employee involvement and empowerment in process
improvement, while Industry 4.0 technologies enhance collaboration and communication through digital platforms.
By fostering a culture of innovation and collaboration, companies can engage employees in leveraging Industry 4.0
technologies to drive operational excellence and sustain competitiveness.
What are the challenges and barriers that
companies may face when adopting lean
manufacturing, Industry 4.0, and
integrating Industry 5.0 technologies?
Human-Machine Collaboration

Personalization

Sustainability

Cultural Resistance

Integration complexity
MDM Company June 1, 2021

What are the challenges and barriers that companies

may face when adopting lean manufacturing and
Industry 4.0 technologies?
Are you ready?
Resistance to Change

Technology Integration

Data Management and Privacy

Skill Gaps and Training

Cost and ROI Concerns

What are the future trends and opportunities in lean manufacturing and Industry 4.0 that
companies should be prepared for?
Digital Transformation

Automation and Robotics

Supply Chain Resilience

Sustainability and Circular Economy

Skills Development and Workforce Transformation

what are the before and after integrating industry 4.0 in lean manufacturing ?

Enhanced Connectivity
Data-Driven Insights
Automation and Efficiency
Flexibility and Adaptability
Innovation and Competitiveness
BEFORE
Before integration, manufacturing processes may operate in
isolation, leading to limited communication and collaboration
between systems.
Before integration, decision-making may rely on manual analysis
and historical data, limiting visibility into real-time performance
and predictive analytics.
Before integration, manual tasks and repetitive processes may
slow down production and increase the risk of errors.
Before integration, rigid production systems may struggle to
adapt to changing market demands and customer preferences.
Before integration, companies may lag behind in innovation and
struggle to stay competitive in a fast-paced market.
AFTER
After integrating Industry 4.0, companies can achieve enhanced
connectivity through IoT devices, cloud platforms, and digital twins,
enabling real-time data sharing and seamless integration across the
production chain.
After integration, Industry 4.0 technologies enable companies to harness
big data analytics, AI algorithms, and machine learning to gain
actionable insights, optimize processes, and drive continuous
improvement based on data-driven decisions.
After integration, automation technologies such as robotics, AI-driven
automation, and smart sensors can streamline operations, reduce human
intervention, and enhance operational efficiency, leading to increased
productivity and cost savings.
After integration, companies can achieve greater flexibility and
adaptability through agile manufacturing practices, digital twinning, and
dynamic production scheduling, allowing for rapid adjustments,
customization, and responsiveness to market shifts.
After integration, leveraging Industry 4.0 technologies in lean
manufacturing can drive innovation, foster a culture of continuous
improvement, and position companies as industry leaders by offering
innovative products, services, and customer experiences.
What are the Differences between Lean Manufacturing and Six
Sigma ??
 Focus on Focus on Lean simplifies and streamlines
 eliminating waste  reducing defects processes, while Six Sigma uses
 continuous improvement  improving quality through statistical methods for quality control.
 efficiency data-driven analysis.
 Real Case Study

Comparison of Operational Performance

Before and After the Adoption of Industry 4.0 Technologies with Lean
Manufacturing and Six Sigma
Company Overview and Context

BO S C H
campany

Company: bosch
Industry: Manufacturing of electronic and electrical
components
Location: Amberg, Germany
D Improvement through LM and Six Sigma Principles

Identified Problems:

• Issues with coordinating and synchronizing

different stages of production.
• Decisions based on historical data, slowing
down responsiveness(réactivité).
• Bottlenecks in the production line leading
to delays and inefficiencies.
M Process evaluation using Lean and Six Sigma
Key Performance Indicators (KPIs) :
• OEE (Overall Equipment Effectiveness):
70%
• Average Cycle Time: 50 minutes
• Defect Rate: 4%
• Unplanned Downtime: 8 hours per week
Value Stream Mapping(VSM ):
• Key Metrics: Process times, wait
times, inventory levels, and defect
rates.
• Identified Issues: High levels of
work-in-progress inventory, long
wait times between processes,
bottlenecks in certain production
stages, and high defect rates.
A Strategies for Integrating Industry 4.0
Technologies
Deployed Technologies:

Internet of Things Big-Data Analytics: Automation and

(IoT)
Robotics:
I Internet of Things (IoT)
Smart
sensors a
connecte d
devices.
n
d

•Inventory Management: Predictive Maintenance:

LM: Reduces 6σ : reduce LM: 6σ : Uses

waste by variability in Minimizes accurate
maintaining inventory unplanned data to
optimized management downtime,. reduce
inventory levels processes. defects

Big Data and Analytics:

I •Process Optimization:
Big Data Analytics:

• Quality Control:
analytics
platform
and mach
s
learning ine
algorithm
s.

6σ : Uses LM: 6σ : Prevents

LM: eliminates
statistical Continuously defects
non-value-
data analysis. improves through real-
added
product time data
activities,
quality analysi
optimizing
production
flows

Automation and
Robotics:
I • Workflow Automation: :
Automation and Robotics:

•Material Handling
Autonom
robots.
ous

LM: 6σ : Reduces
errors and LM: 6σ :
standardizing
variability. Optimizes Improves
and
material efficiency
automating
flow, and reduces
repetitive tasks.
reducing variability in
delays and material
unnecessary handling
movements
C Results After the Adoption of Industry 4.0 Technologies
C Results After the Adoption of Industry 4.0 Technologies

Overall Impact:

•Operational Efficiency: Faster processes,

less downtime = higher productivity.
•Product Quality: Fewer defects and
consistent quality.
•Flexibility: Ability to quickly adapt to
changing customer needs.
•Data-Driven Decisions: Real-time data
analysis for better decision making.
Conclusion

Adopting and integrating new 4.0 technologies is crucial to remain

competitive. Process improvement through these technologies
optimizes performance and addresses challenges of an evolving
industrial environment. Investing in technological innovation
maintains a competitive edge and ensures sustainable growth.
Thank you

for your attention