Lean Principles Meet Digitalization
Identify waste, streamline processes and further optimize value creation through digital technologies - experienced hands-on using real-world infrastructure.
Der Lernbaustein „Schlanke Digitale Produktion“ verbindet klassische Lean-Prinzipien mit den Technologien der Industrie 4.0 – erlebbar, handlungsorientiert und ohne Vorkenntnisse. In einem 120-minütigen Praxisworkshop im Industrial Transformation Lab (InTraLab) durchlaufen die Teilnehmenden einen simulierten Produktionsprozess in drei progressiven Stufen: vom verschwendungsbehafteten Ausgangszustand über die klassische Lean-Optimierung bis zur digital optimierten Smart Factory. So wird der gesamte Transformationspfad in nur zwei Stunden greifbar.
Rather than attending traditional classroom-style instruction, participants identify, eliminate and optimize waste themselves using real Industry 4.0 infrastructure. A real-time dashboard immediately shows how the improvements affect lead time, costs and scrap rates. The module is deliberately designed to be accessible to production employees, shop-floor workers and machine operators, and was developed using the Design Science Research methodology and evaluated by experts.
Target Group: Production Employees with No Prior Lean Experience
Lernziele
Grundprinzipien des Lean Ansatzes kennenlernen, ausprobieren and verinnerlichen.
Prozesse selbst optimieren and digitalisieren können.
Course Structure
Dauer: 0,5 – 1 Tag
The workshop consistently alternates between short theory (T) and practical (P) sessions:
Introduction – Objectives and Overview of the Four Learning Goals
T1 – Recognizing Waste
The 7 Types of Waste According to Ohno, Illustrated with Real-World Examples (KTM, Tesla, GM, Boeing)
P1 – Identifying Waste
Running the Process Variant “Classic” with Built-In Waste in a Simulated Production Process
T2 – Principles and Methods
Lean tools such as Kaizen, 5S, Flow Principle, Zero-Defect Principle and Jidoka
P2 – Eliminating Waste Running the Variant “Classic without Waste” – methods are applied in practice
T3 – Digital Opportunities for Further Optimization
Industry 4.0 and Cyber-Physical Systems as the next lever for optimization
P3 – Process Optimization
Running the Variant „Digital optimiert“ – Smart Factory in action
Conclusion – transfer and reflection, including a checklist for Your own organization
Ihr Mehrwert
In nur einem Tag erlangen Sie die Fähigkeit, selbstständig Prozesse zu optimieren.
Sie erlernen die Fähigkeit einfache digitale Werkzeuge zu entwickeln and einzusetzen.
Keywords
Lean Digital Production, Lean Management, Lean Production, Lean Manufacturing, Industry 4.0, Smart Factory, Learning Factory, Digital Transformation, Production Optimization, Process Optimization, Waste Reduction, Seven Types of Waste, TIMWOOD, Overproduction, Waiting, Transportation, Processing, Inventory, Motion, Defects, Toyota Production System, Kaizen, Continuous Improvement Process, 5S Method, Flow Principle, One-Piece Flow, Kanban, Pull Principle, Just-in-Time, Takt Principle, Zero-Defect Principle, TPM, TQM, Jidoka, Autonomation, Poka-Yoke, Cyber-Physical Systems, Digital Twin, Predictive Maintenance, AI-Assisted Maintenance, Computer Vision, Quality Assurance, Autonomous Mobile Robots, AMR, Augmented Operator, Augmented Reality Maintenance, AR Remote Maintenance, Digital Shop Floor Management, Key Performance Indicators, Lead Time, Production Training, Industry 4.0 Hands-On Workshop, Industrial Transformation Lab