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Kaizen in smart manufacturing (SM) projects: framework and examples of improvement areas

Gajdzik Bożena

Zeszyty Naukowe. Organizacja i Zarządzanie / Politechnika Śląska

2023

z. 169

281--299

Purpose: The fourth industrial revolution has a strong influence on changes in enterprises towards smart manufacturing. Technological progress and digital economies created new conditions for business. Currently producers aiming at digitalization of processes and smart manufacturing based on key technologies (pillars) of Industry 4.0. In transformation process, the question arises, from what to start the changes and which path to choose to smart manufacturing (SM). Apart from big projects of SM, changes need the concept of Kaizen based on small steps of changes on workstations towards smart production. The purpose of the paper is the presentation of links between Smart Manufacturing (SM) projects and Kaizen. Design/methodology/approach: The paper was realized based on literature review and examples of SM projects. Findings: The study found that Kaizen is evolving with the automation and digitisation of production. IC technologies facilitate Kaizen improvements. The automation of production processes provides insight into historical data through process monitoring. Fully autonomous equipment is equipped with systems for transferring data to a central decision-making system. The machine operator's job is to collaborate with robots and control machine operation in real time using simple data visualisation and warning systems. Research limitations/implications: The work prepared is of a high degree of generality. Kaizen is implemented at workplaces and is concerned with practical improvements. These improvements are many, following the principle of small steps. The publication focuses on presenting the idea of Kaizen in SM projects. Practical implications: The paper can have an impact on the practical application of Kaizen in SM projects as it presents examples of Kaizen improvements. Originality/value The topic of adapting Kaizen to SM projects is a new area of research that will be strongly built upon due to the utility of Smart Kaizen.

Concept of reconfigurability in interoperation manufacturing buffers for smart factory

Grznár Patrik, Mozol Štefan, Vavrík Vladimír, Gabajová Gabriela, Furmannová Beáta

Quality Production Improvement - QPI

2019

Vol. 1, Iss. 1

575--582

In this article, it is described how the reconfigurable inter-operational buffers system built on the Digital Twin platform. Interoperating production buffers are now widely used in production. Their effect on the production system can be seen in decreasing downtime. From a cost-based point of view, the interoperating production buffers may generate a gain from the reduction in the volume of work-in-process, with which we increase production performance. This ratio depends on the average number of products that the buffers contain. The average number of pieces in the buffer is limited by the capacity of the buffer. The impact of turbulence in production is seen precisely on the average content of inter-operational production buffers. If we want to maintain work-in-process on optimal values, it is necessary to calculate and maintain the optimal capacity of each interoperating production buffer on the line. In the context of Smart Factory, it is currently possible that the current capacity of the interoperating production buffers is maintained according to the current state of production. In the subject system, real production facilities communicate with each other through the IoT as autonomous agents, which are decided on the basis of a formula to calculate the optimal capacity of the buffers, the prediction of faults and negotiation, thus actively maintaining the optimal capacity of intermediate operating production buffers for Smart Factory support.