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Learn how Automation can work with Lean and other process improvement methodologies.
Check out the Omnatec guide for cost-effective solutions to increase throughput!
A step-by-step guide to process optimisation and increasing throughput.
Step 1 – Identify the process
Taking a page from the Theory of Constraints (TOC) is perfect here. Improving a subprocess which is limiting your overall potential is a great way to improve your overall throughput. Using a Gemba walk or possibly a more in-depth Value Stream Mapping activity are ideal ways to identify a “bottlenecked” process for you to begin with.
Looking around your factory for excess Work in Progress (WIP) or large amounts of lineside inventory as well as talking to the operators on the floor to find out where they end up waiting around before they can finish their task are good ways to start identifying your bottleneck.
Step 2 – Eliminate waste
Once you have found a process to focus on, we use a few more Lean tools to reduce waste. 5S is a great place to start to improve worker efficiency and ergonomics. Also, look at the travel distance for the materials, tools, and workers to complete the step. Look to eliminate unnecessary transport steps.
By reducing any waste, we make the bottleneck as efficient as possible and focus the time we have on Value-Added steps. Learn why waste reduction is such a powerful tool for increasing throughput: omnatec.com/lean-part-1/
Step 3 – Automate
Automation is one of the first things people think about when they are looking to increase throughput. However, automating a process that is not currently the limiting step within your process will not have any effect on the overall process throughput. However, it can be used to:
It is important to keep an eye on your overall process so that any throughput improvements don’t push your bottleneck somewhere unexpected.
Any optimisation through automation should be targeted. It should match the throughput to either the next most constrictive bottleneck or the overall desired throughput of the factory.
Contact us to find out how fully or semi-automated solutions could help you. Get some examples of case studies about how other manufacturers have benefited.
Step 4 – Feed the Bottleneck
it is important to remember that any time lost when your bottleneck is not running is lost forever.
You cannot make it up.
So, it is crucial that you ensure the processes upstream of the bottleneck have suitable bandwidth and a high enough Overall Equipment Efficiency (OEE) to feed the bottleneck. This is especially important if any automation has been implemented to help increase the throughput of the bottleneck. Historical cycle times will no longer be valid and other processes may need to be improved to keep up with the new drumbeat.
Step 5 – Sustainability
What effect have the changes made? It is critical to get regular feedback by
By managing the change and ensuring there is a long-term approach to any improvements, falling back into old habits is prevented and you ensure your processes are well controlled.
Consistency is key!
Step 6 – Identify the process again
Restart the process!
We need to ensure the bottleneck hasn’t moved.
We need to monitor the capacity of the current bottleneck.
We need to review the metrics for any new automation and any upstream processes.
Optimisation requires continuous improvement!
Let us know what you need!
Hopefully, our guide has answered the question of whether you should use lean or automation. The Omnatec approach can be considered an Augmented Lean where the best solution for the customer is achieved. Very often this is a low cost process improvement exercise or a small scale automation solution.
