Process optimization with lean manufacturing

Lean manufacturing, literally “lean production”, is a specific approach to managing production processes, the main assumption of which is the economical and responsible management of resources. In the implementation of such a concept, process optimization plays an important role, which can be achieved, among others, with the support of CMMS systems . What is worth knowing about it?

What is lean manufacturing?

At the beginning, it is worth introducing the concept of lean manufacturing – it is a philosophy of production management, the aim of which is to eliminate waste and maximize the value delivered to the customer. The basis of this concept is the assumptions of the Toyota Production System (TPS). Toyota was the first manufacturing company to implement such an approach, but its success caused lean manufacturing to be used in many other plants and other industrial sectors. This system focuses on improving processes by reducing unnecessary activities, optimizing workflow and effectively managing resources.

It is easy to see that with such assumptions, CMMS systems – Computerized Maintenance Management Systems (CMMS systems) play an important role in the implementation of lean manufacturing. This is due to the fact that digital support in maintenance allows for effective planning, monitoring and ongoing optimization of maintenance activities. This in turn significantly affects cost reduction, as well as improving operational efficiency and increasing machine availability.

The Role of CMMS Systems in Lean Manufacturing

CMMS systems are a perfect fit for lean manufacturing principles, as their functionality largely overlaps with the most important goals of using this approach to production. The most important benefit in this case is better resource management, which translates into the possibility of eliminating waste; in addition, there is also an improvement in the flow of information and the decision-making process. Data recorded in CMMS systems also allows for more effective maintenance planning , which leads to a reduction in the risk of failures and unplanned downtime. All this contributes to increased operational efficiency – thanks to such software, companies can implement the key assumptions of lean manufacturing and constantly improve their production processes.

Eliminate waste in maintenance with CMMS

Lean manufacturing identifies seven types of waste (referred to as “muda” – Japanese for “unnecessary”, “redundant”) that are to be eliminated through the application of appropriate manufacturing practices. For each of these, it is possible to identify CMMS capabilities that will allow for the elimination of waste in the plant:

1. Overproduction – greater certainty regarding the condition of machines, as well as avoiding unnecessary downtime and failures, allows for a more stable flow of production processes.
2. Waiting – Automating maintenance planning significantly reduces the waiting time for equipment availability.
3. Unnecessary transportation – CMMS systems enable better management of spare parts, which leads to minimization of unnecessary movement of components.
4. Unnecessary technological processes – using CMMS software, you can, for example, eliminate inefficient service procedures.
5. Excess inventory – CMMS also supports spare parts inventory management, preventing overstocking.
6. Unnecessary movement – ​​digitization of documentation along with automation of assigning service orders allows to reduce the time and effort involved in organizing the work of maintenance departments.
7. Quality defects – CMMS provides essential support for preventive maintenance objectives that help minimize the frequency of equipment failures and resulting manufacturing defects.

It is worth noting that these are both aspects directly related to production, as well as the functioning of the entire plant. This means that the CMMS system offers comprehensive support in various areas related to the implementation of the lean manufacturing concept.

Maintenance planning and automation with CMMS systems

One of the greatest advantages of CMMS software is the ability to implement a proactive maintenance strategy . This is crucial in the lean manufacturing approach. Thanks to features such as preventive planning, failure prediction based on historical data analysis, automatic task assignment or monitoring of performance indicators, CMMS systems allow for better management of production and machine maintenance. This in turn translates into the ability to eliminate unplanned downtime, extend the life of machines and reduce operating costs.

Reduction of failures and efficient management of spare parts

Unplanned failures are a significant threat in every production plant – such situations can generate high costs and disrupt the smoothness of production processes. However, CMMS allows for a significant reduction in the number of failures by monitoring the condition of machines on an ongoing basis, quickly identifying recurring problems, analyzing trends and a predictive approach to maintenance. Thanks to this, it is possible not only to respond to failures more effectively, but also to prevent their occurrence. This aspect fits perfectly into one of the foundations of the lean manufacturing concept – the philosophy of continuous improvement ( kaizen ).

In addition, CMMS helps solve problems with inefficient spare parts management. The most important in this respect are real-time inventory levels tracking, automatic ordering of parts according to forecasted consumption, and minimizing the risk of downtime resulting from the lack of necessary components. As a result, companies can achieve a balance between availability and storage costs, which also fits the assumptions of lean production.

CMMS systems – invaluable support in implementing lean manufacturing concepts

Due to the functionality offered, CMMS systems play a key role in optimizing processes in accordance with the lean manufacturing philosophy. By reducing waste, automating maintenance, effectively managing resources, and digitalizing processes, this type of software allows, among other things, to increase the effectiveness of the company’s operations while reducing costs. By implementing a CMMS system, companies can minimize failures and downtime, as well as systematically improve their results and adapt to changing market conditions. To learn more, please contact QRmaint.