Lean production in automation

Lean production is a production principle originally coined by car manufacturer Toyota. Among other things, it aims to manufacture as efficiently, clearly and resource-efficiently as possible without compromising on quality.

Lean approaches are also indispensable in automation technology today – because here, too, the aim is to make automated systems as efficient, flexible and waste-free as possible.

Production systems that follow the lean principle often include manual workstations that are supplemented by partial automation for recurring or ergonomically unfavourable work steps. Designed for flexibility and adaptability, lean production systems are a counter-design to complex, fully automated systems, which can score points with large batch sizes.

Lean production in automation

Manual and automatic assembly, testing and packaging of an automotive interior part on an Autec system

In automation technology, lean production stands for, among other things:

  • Targeted instead of maximum possible automation – i.e. only where it is economical, sensible and process-reliable.

  • Standardisation of processes and systems to reduce sources of error

  • (Partial) automation, especially for recurring or non-ergonomic work steps

  • Avoidance of over-automation (‘automation for automation’s sake’)

  • Flexibly scalable automation solutions for smaller batch sizes and a wide range of variants

Key facts on the subject of lean-based manufacturing concepts are listed below.

When it comes to production automation, lean is one option – but possibly not the only one: we analyse, compare and implement the assembly concept that makes the most sense for you, both technically and economically.

The advantages of lean-based manufacturing concepts

  • Cost reduction
    Lower capital commitment than with fully automatic high-end systems.
  • More compact system concepts
    Lean production relies on one-piece flow; each workpiece is therefore passed on individually, directly from station to station – without buffers or intermediate storage and the associated space requirements.
  • Simple scalability
    Lean-based production lines generally utilise easily scalable processes and production concepts.
  • Short set-up times
    Set-up times can be minimised through standardisation and simple devices; ideally, even batch size 1 becomes economically feasible.
  • Flexibility for smaller quantities or a wide range of variants
    Because it can react flexibly to fluctuations in demand, lean-based production is well suited to volatile markets or seasonal products, for example.
  • Better maintainability and reliability
    Lean relies on simple, robust technology. As there are no complex solutions, production can even be continued manually if necessary.

Restrictions on the use of lean-based manufacturing concepts

  • Initial conversion effort
    If lean production is only implemented retrospectively, existing systems often have to be replanned or adapted.
  • Risk of ‘overengineering’
    The balance between too little and too much automation is sometimes difficult.
  • Only suitable for small to medium batch sizes
    Lean often relies on small, flexible teams with a high proportion of manual labour. With high volumes, the number of employees would have to increase significantly – this becomes expensive, inflexible and organisationally demanding.

Conclusion

Lean production in automation means automating intelligently, efficiently and with a healthy sense of proportion – i.e. as simply, flexibly and demand-orientated as possible, without unnecessary complexity or rigid large-scale systems. When applied correctly, lean automation can represent a real competitive advantage – especially with a high number of variants, short product life cycles and limited space or budget.

Ask the automation specialists at AUTEC for the most suitable assembly concept for your specific requirements!