Due to the globalization, we have witnessed the emergence of new challenges, driven by a sharp drop in industrial production costs and a great ability to produce high quality products at competitive prices. To cope with these growing challenges, Industry 4.0 were launched in 2011. This concept represents the digitalization of the industry, integrating resources into production: people, machines and processes. These networked resources can interact with each other. Industry 4.0 optimizes the production system. The plant becomes agile, with flexible production methods, reconfigurable tools, and more efficient. Considering the Lean requirements during the early stages of production system design could facilitate the development of Industry 4.0. This paper mainly focuses on both Lean and Industry 4.0 by considering their requirements during the early stages of production system design. In this study, we analyze the convergence and contradictions for the implementation of these two concepts.
We focus on improving the performance of production machines (timesaving, flexibility, cost-effectiveness, safety) from the early design phase. Lean integration during the design phases might be a more appropriate solution, but this could be a source of some contradictions related to the machine performance and the usage requirements. In this paper, we propose an approach, based on Lean and Inventive Design Methodology (IDM-TRIZ), to identify and resolve these contradictions due to the Lean integration and also to provide innovative technical solutions. The approach is illustrated by the integration of the functionalities of the ''Single Minute of Exchange of Dies'' (SMED) and the ''5S'' method from the early design phase. A case study about the ''3D printer clogged nozzle'' outlines the feasibility of the proposed approach.
Manufacturing needs more and more requirements (sustainability, agility, Industry 4.0 technologies, etc.) to meet customer demands. Nowadays, companies apply Lean tools to improve machines and systems performance in their use phase. Lean tools application on existing machines ensures some functionalities like (Reduce changeover time, eliminate wastes, Involve Human Skills, etc.). The purpose of this paper is to offer designers a design support method and tool to design a performant system (production system, machines, etc.) by integrating Lean functionalities from the early design phases, with a minimum of needs to improve the system in the use phase via Lean. For this purpose, we analyze the Lean principles and tools to identify functionalities provided by Lean. These functionalities are analyzed and classified to integrate them into the design of manufacturing systems in the context of Industry 4.0. A "Lean-System-Design" approach defines a systematic and detailed guide for the integration of Lean from the early design phase. We provide the software tool specifications, which represent the first steps of its implementation. We have illustrated our proposal with a case study on the design of a waste treatment machine.
To understand how industrial designers take into account the information and conditions of use especially the Human Factors and Ergonomics (HFE) from the early design phase, we surveyed more than 50 companies. We analyzed their design work and evaluated if they need a new structured method to provide a real image to understand what is going on in the companies, what they do, use, and how they answer this problem. Also, we proposed to them the method developed by [1], [2], that aims to integrate the human factors and ergonomics (HFE) from the early design phase, and represented in the survey. The objective is, first, to verify the availability of designers to use a new method to help them integrate HFE into their design process and, second, to improve the presented method based on the integration of Lean principles into the design process. The survey has been answered by more than 50 experts in engineering design, which represented companies in France, Germany, and internationally in different sectors of activity such as machinery and equipment, industrial materials, automotive equipment, and products, in which we found quite a few cases of interactions between humans and machines.
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