LEAN 4. 0 – ALGORITHMIC SUPPORT FOR OPTIMIZING PRODUCTION DECISIONS

1. DBR77
LEAN 4. 0 – ALGORITHMIC SUPPORT FOR
OPTIMIZING PRODUCTION DECISIONS
10.2022
Piotr Wiśniewski, PhD

2. Tychy Chełmek 1 Chełmek 2
Maflow China
Maflow France
Maflow India
Maflow Italy
Maflow Spain
Maflow Brazil
Maflow Mexico
Digitalization Experience

3. SPECIFICATION TECHNOLOGY DECISION IMPLEMENTATION OPTIMIZATION
CONTRACTING
1 MONTH 6 MONTHS 3 MONTHS 3 MONTHS 6 MONTHS 6 MONTHS
25 MONTHS
TIME
COST 5 % 15 % 5 % 5 % 60 % 10 %
Robotization of the Production Station
01 02 03 04 05 06

4. CONNECTIVITY COMPUTING DATA
Digitalization

5. 3x Digital Transformation
PROCESS DIGITIZATION DIGITAL PRODUCTS DIGITAL BUSINESS MODELS

6. MARKETPLACE
OPTIMIZATION BY AI
DIGITAL TWIN
THE ALL-IN-ONE PLATFORM
FOR THE BEST ROBOTIZATION
Digital Industry Disruption

7. OLD STYLE DIGITAL
Static 2D design Dynamic 3D modeling
• Long and inflexible
process
• High price of design
• Fast and precise
• Presentation of all production
system
01 Specification

8. 01 Specification

9. OLD STYLE DIGITAL
Searching for technological
solutions
Proposals for solutions on the marketplace
• Time-consuming
• A small number of
solutions
• Many different solutions
• Comparability of technology
02 Technology

10. 02 Technology

11. OLD STYLE DIGITAL
Difficult decision-making process Full transparency of offers
• Offers hardly comparable
• Specialized knowledge
required
• Consistent methodology for
comparisons
• VR and AR presentation
03 Decision

12. VR/AR
03 Decision

13. OLD STYLE DIGITAL
Expensive and difficult
contracting
Reliable and automatic contracting process
• Lengthy negotiations
• Integrator verification
difficulty
• Selection of integrators for orders
• Simple contracting process
04 Contracting

14. Partners
04 Contracting

15. OLD STYLE DIGITAL
Delays and budget changes Work according to the methodology of project
management
05 Implementation

16. OLD STYLE DIGITAL
VSM Lean 4.0
06 Optimization – Lean 4.0

17. 06 Optimization – Lean 4.0
DATA REPORTS PLANS SIMULATIONS AI
1# 2# 3# 4# 5#
LEAN
4.0
IoT MES 3D Studio Digital
Twin
VR/AR
Algorithms

18. Production Cels Production Lines
Warehouse Intralogistics
Work Resources Entire production
facility
 Increase in the efficiency of implemented
processes
 Acceleration in prototyping of new cels, lines
or entire plants
 Reduction of the number of design errors in
production processes
 An algorithmic support of decision-making
processes
WHAT OUTCOMES CAN YOU EXPECT?
Digital
Twin
06 Optimization – Lean 4.0

19. OEE
optimization
MPS
Production
plan
Schedulin
g
productio
n
Prediction of
machine downtime
Material
Management
Intralogist
ics
Optimizatio
n
06 Optimization – Lean 4.0
AI
algorithms
WHAT OUTCOMES CAN YOU EXPECT?
 Process optimization
 Rapid decision-making tool driven by production
events
 Decisions based on a wide variety of data
 Algorithms improve their recommendations over time
 No human error factor

20. 06 Optimization – Lean 4.0

21. SPECIFICATION TECHNOLOGY DECISION IMPLEMENTATION OPTIMIZATION
CONTRACTING
1 MONTH 6 MONTHS 3 MONTHS 3 MONTHS 6 MONTHS 6 MONTHS
25 MONTHS
TIME
COST
5 % 15 % 5 % 5 % 60 % 10 %
01 02 03 04 05 06
0 MONTH 2 MONTHS 1 MONTHS 1 MONTHS 5 MONTHS 3 MONTHS
1 % 10 % 2 % 2 % 50 % 5 %
12 MONTHS 70% COST
Digital Industry Disruption

22. 50 % 30 % 20 %
DBR77 outcomes and benefits
REDUCTION
OF DEVELOPMENT TIME
REDUCTION
OF ROBOTIZATION CAPEX
INCREASED
PRODUCTIVITY