Abstract
Manufacturing needs more and more requirements (sustainability, agility, Industry 4.0 technologies, etc.) to meet customer demands. Nowadays, companies apply Lean tools to improve machines and systems performance in their use phase. Lean tools application on existing machines ensures some functionalities like (Reduce changeover time, eliminate wastes, Involve Human Skills, etc.). The purpose of this paper is to offer designers a design support method and tool to design a performant system (production system, machines, etc.) by integrating Lean functionalities from the early design phases, with a minimum of needs to improve the system in the use phase via Lean. For this purpose, we analyze the Lean principles and tools to identify functionalities provided by Lean. These functionalities are analyzed and classified to integrate them into the design of manufacturing systems in the context of Industry 4.0. A "Lean-System-Design" approach defines a systematic and detailed guide for the integration of Lean from the early design phase. We provide the software tool specifications, which represent the first steps of its implementation. We have illustrated our proposal with a case study on the design of a waste treatment machine.
Highlights
Today many companies apply Lean principles and tools to their manufacturing systems to fulfill some performance criteria
According to Lean expert Hohmann [1], Lean worksites focus on local problems or a given area, regardless of the links, interactions, and impacts in other areas, which makes that the improvements are not optimal and does not cover the whole manufacturing system
Most of these methods mentioned in the literature are: either theoretical, based on Lean thinking, but they are not detailed enough to cover all performance criteria and appropriate functionalities, or they focus on one phase of a system's life cycle more than another
Summary
Today many companies apply Lean principles and tools to their manufacturing systems to fulfill some performance criteria. They do that because the designed systems are not always optimal and need sometimes some improvement to increase their performance. The application of Lean tools requires a particular organization, and it is limited by the designed system or the machine itself. Most of these Lean tools require time and budget to be invested for the implementation of a continuous improvement project either by the company's teams themselves or by calling on Lean experts. The operator can perform his tasks without losing time in optimal work-
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