Digital Lean has been a hot topic in recent years as a way of increasing productivity and adding efficiency to processes in different organizations. The secret to why lean tools work so well in manufacturing and other industries lies in their data-based nature and emphasis on eliminating waste. They bring value through data by supporting smart decision making and tracking the roots of issues standing in the way of a thriving smart factory. Lean tools are said to be optimal for identifying hidden issues and emphasizing continuous improvement. But how to get started on your lean journey towards a modern smart factory?
Nearly one third of manufacturers feel hesitant to get started with smart factory initiatives due to lack of experience, difficulty in adapting, lack of compelling business case or lack of overall strategy. Using a ready-made, easy-to-use tool helps tackle one of the major obstacles in implementing lean tools to a factory’s everyday operations: whereas before a software development project has possibly taken years and required significant financial investments, ready-made tools help you get started in even just a few days. The best ones are tools that allow new modules to be easily added as needed when you begin to scale smart factory initiatives around your organization. This makes taking the digital jump a whole lot less overwhelming.
Digital Andon is one of Fliq’s Lean tools that helps to commit workforce, strengthen a team, and increase productivity. It’s a communication system that communicates with your whole organization in real time and is suited for any production facility. Digital Andon works efficiently by letting you send out messages, alarms, and maintenance calls even with just one push of a button. With the help of this tool, the organization can develop better operating models that save time, make team communication easier, increase quality and productivity, and minimize risks related to different operations. The visually clear and color-coded Digital Andon reacts to unusual events, alerting people of charge to the scene, and offering solution options for the situation to help quicker decision making.
So, how does it work in practice? When an error or malfunction happens, a maintenance call is made through Digital Andon to a pre-determined recipient who will receive the maintenance calls in real time. This way the person in charge of fixing the issue can let you know the response time and maintenance plan more efficiently. The maintenance call can include any necessary extra information such as the extent and criticality of the issue or a free worded explanation of the problem. All information will be stored for later processing.
Implementing ready-made tools also makes it possible to carry out efficient testing and find just the right solutions for your factory – tackling another obstacle where manufacturers get caught up in digital technology that does not necessarily solve the problems in the process that most need solving. Digital lean makes room for getting to the root of issues and continuous improvement, giving you the best value for your investment.
One of the core thoughts behind digital lean is to think big, start small, and scale fast. Thinking big establishes the vision, followed by a digital foundry that sets a mission and a strategy. After this, it’s good to start small with a pilot case in a clear, existing workstream or product that is known well in your factory. Results can be seen more clearly when there is an old way of operating to compare the new tools with. The last step, scaling fast, is the one that brings business value as most manufacturers notice results when the initial pilot is scaled to other areas. In case expected value is not met, it is important to analyze why – and continually improve process to achieve the target set.
Digital Lean is the simplest way to start digitalizing your factory floor and choosing the right lean partner makes the process even easier. Fliq’s Digital Lean service has been developed for several years in co-operation with large global companies implementing lean tools in their operations. We know how to help you get started and want to do our best to grow with you on your smart factory journey.
To recap, here are a few benefits choosing the digital lean path can bring you:
So, what’s the easiest way to get started? Digital Andon is a maintenance call service that can be implemented effortlessly and quickly into any factory’s operations. It is the base of Fliq’s Digital Lean BASIC service that sends out messages, alarms, and maintenance calls even with just one push of a button. In accordance with the lean philosophy, it helps you eliminate waste – in this case production errors and bottlenecks efficiently when they arise. Payback begins right from the first Andon call, increasing your factory’s productivity to a new level.
Want to learn more about Fliq’s Digital Andon? Download more information here: FLIQ Digital Lean (pdf)
SOURCES:
Digital lean manufacturing – Industry 4.0 technologies transform lean processes to advance the enterprise
2019 Deloitte and MAPI Smart Factory Study – Capturing value through the digital journey
