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I’ve long been interested in the confluence of automation, software, and Lean. I reached out to a few leading Lean practitioners and consultants for the first issue of Automation World in 2003. They responded that Lean is a manual process and any hint that automation or software would be useful was unthinkable.

I convinced a couple that trustable data was essential for Lean and that data coming directly from the automation was trustable. So, I ran a Lean article for issue 1 revisiting the topic at times throughout my 10 years as editor there.

This article from Inductive Automation’s blog came my way the other day. It is a good look at the current state of MES and Lean. I’ll highlight a few topics. Check it out yourself.

Using MES Powered By Ignition To Accelerate Lean Manufacturing Goals by Danny Haskell, NeoMatrix, Inc., guest author.

Staying competitive means manufacturers constantly seek ways to enhance operational efficiency, minimize costs and waste, and maintain the highest standards of product quality. Whether a manufacturer is just beginning to explore manufacturing execution systems (MES) or looking to optimize an existing MES infrastructure, and whether they use Sepasoft’s MES modules for the lean manufacturing software Ignition or build their own custom MES solutions, Ignition MES offers manufacturers a versatile solution to streamline production, improve visibility, and accelerate lean manufacturing initiatives across the factory floor.

Data remains the key

Driven by advancements in Digital Transformation and the adoption of Industry 4.0 technologies, MES solutions enable real-time data integration and enhanced automation, significantly improving production processes and promoting lean manufacturing. Manufacturers adopting MES solutions have reported improvements in operational efficiency of 15-20% and reductions in production lead times of 10-15%.

Haskell identifies some key trends:

  • Predictive Maintenance: MES technology helps manufacturers anticipate equipment failures before they occur, reducing downtime and maintenance costs.
  • Digital Twins: Manufacturers use digital twins to create virtual replicas of manufacturing processes and equipment, enabling manufacturers to simulate and optimize operations without physical testing.
  • Reshoring and Local Production: With supply chain disruptions and the need for resilience, some manufacturers are reshoring their operations to reduce the reliance on overseas suppliers and enhance supply chain flexibility.
  • Sustainability and Carbon Neutrality: Environmental, social, and governance (ESG) initiatives push manufacturers to adopt sustainable practices, such as reducing emissions, using renewable energy, and adopting eco-friendly production processes.
  • Industrial Automation and Robotics: Manufacturers integrating robots and AI enable more autonomous and smart manufacturing processes, improving productivity and precision. This trend also extends to collaborative robots (cobots) that work alongside human employees to streamline operations.
  • Advanced Data Analytics and AI: Utilizing data analytics and AI to monitor production, improve quality control, and predict maintenance needs is becoming increasingly important to optimize processes and make data-driven decision-making.
  • Cloud Computing and IIoT: Adopting cloud solutions and Industrial Internet of Things (IIoT) technologies, manufacturers can connect machines, systems, and processes for better data sharing and real-time monitoring.

He continues with several specific examples. Check it out for yourself.

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