Lean Principles Meet Digitalization
Identify waste, streamline processes and further optimize value creation through digital technologies - experienced hands-on using real-world infrastructure.
The “Lean Digital Production” learning module combines classic lean principles with Industry 4.0 technologies in a hands-on, action-oriented format that requires no prior knowledge. In a 120-minute practical workshop at the Industrial Transformation Lab (InTraLab), participants work through a simulated production process in three progressive stages: from an initial process characterized by waste, through classic lean optimization, to a digitally optimized smart factory. This makes the entire transformation journey tangible in just two hours.
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
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
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