Lean Into It (Part 4)

Practical applications for modern manufacturing solutions that fix real-world problems. 

A practical and straightforward explanation of how connected process control technologies can solve manufacturers’ problems. That doesn’t seem like too much to ask, right? Unfortunately, even at a time when a rapidly expanding ecosystem of powerful and sophisticated new manufacturing technologies is more accessible and impactful than ever, that explanation is often missing.

This four-part series of blogs is designed to address that gap, replacing sales language and vague promises with clear and concise breakdowns that give manufacturing professionals the foundational information they need to make thoughtful decisions about technology investments that will effectively (and cost-effectively) address their pain points.

The three previous installments in this series covered six of the eight lean wastes succinctly expressed in the classic DOWNTIME acronym. Here, in part four, we will discuss the final two wastes: Motion Waste and Excess Processing.

Motion Waste

Motion waste is a problem that often stems from (or is related to) other lean wastes. If a station is crowded with excess inventory, for example, it may be difficult to avoid motion waste. An operator being forced to walk to retrieve a part, or even to stand up and stretch to pick something out of a bin may seem like a small issue, but it becomes magnified over time. Wasted seconds turn into wasted minutes, wasted hours, and wasted dollars, all with a corresponding impact on comfort, wellbeing, and job satisfaction.

The connection between innovative manufacturing technologies and motion waste might not be immediately evident, but its impact is profound and potentially transformative. Leading connected process control solutions address motion waste issues in two ways: 1) giving manufacturers new tools to makes processes and production environments more efficient and user-friendly, and 2) utilizing detailed data-gathering and real-time reporting to reveals hidden inefficiencies. The result is a kind of guidebook for station design that manufacturers can follow. It explains how to implement simple steps to achieve not just ergonomic improvements on a station and plant level, but the corresponding procedural optimization that makes it all possible.

Excess Processing

Excess processing is closely related to motion waste. It describes any avoidable, extraneous, redundant, or unnecessarily complex element of the production process. Connected process control solutions avoid wasteful excess processing in multiple ways.

First, by incorporating a sufficient degree of automation and monitoring so that operators aren’t forced to do things like push a button every time they complete a step. By having the system work with the operator, not secondarily, the system simply “knows” if a task has been completed correctly and moves to the next step. Perhaps most impactfully, however, is the ability of leading solutions to optimize and refine process improvements by analyzing the efficacy of changes without disrupting production. Because leading solutions are fully scalable, such refinements can be verified on a single model line or station before being scaled up to all operators. In other words: it allows manufacturers to achieve the holy grail of lean manufacturing: true continuous improvement.

A Leaner, Smarter Future

Popular adoption of even the best and most exciting new technologies always comes with the potential for a learning curve or adjustment period. But among the many reasons why connected process control technology is such an appealing investment for growing numbers of manufacturers is because this is a fully mature space—complete with proven solutions. The reality is that the best of the new generation of manufacturing technologies provides the kind of connected process control functionality that streamlines and simplifies, yielding measurable results in a short amount of time. It’s sophisticated innovation that clarifies instead of complicates.

Simplicity. Clarity. Efficiency. Control.

Even better, because each of the eight lean DOWNTIME wastes is connected to others, improvements in one space have a positive ripple effect with a cascade of complementary benefits that can yield greater-than-expected outcomes. One recent client was spurred to invest in a connected process control solution after determining that a 10% increase in throughput would make a $1.3 million annual difference to their company’s bottom line. Instead of the hoped-for 10%, the manufacturer realized a subsequent 35% increase in throughput. These are the kind of transformative results that manufacturers are seeing, and it’s why leading connected process control solutions are driving the industry forward toward a leaner, smarter, more profitable future.

Learn how Epicor can help streamline your processes and support your lean manufacturing goals.