<p>This research explores the integration of Industry 4.0 (I4.0) and Lean Manufacturing, with the aim of bridging the gaps between theoretical advancements and practical industrial applications. Industry 4.0 offers a set of advanced technologies that can significantly enhance Lean Manufacturing methodologies, particularly in the area of digitalizing Lean tools. The formulation and implementation of Kanban 4.0 within the I4.0-Lean framework represent the core of this study, since Kanban serves as the center of information and data processing, as well as inventory and materials management. In this framework, Value Stream Map (VSM) icons such as Production Kanban, Supermarket, and Withdrawal Kanban are transformed into actionable push buttons, which are part of a novel Kanban 4.0 system design named “Central Digital Kanban Board”. This system integrates all processes into a single web-based solution. The actions of these push buttons are stored in the database, replacing the physical Kanban cards with digital ones, and enabling real-time calculation of Overall Equipment Effectiveness (OEE) for individual machines and integrated OEE for the entire system through digital dashboards. In addition, the actions of these push buttons result in the digitalization of the Value Stream Map (VSM 4.0), including real-time calculations of cycle, takt, changeover, and inventory times. Also, the inventory quantity, total production lead time, and value-added time are calculated to provide comprehensive real-time performance metrics for the system. To fully integrate the system within the I4.0-Lean framework, the information shared with Enterprise Resource Planning (ERP) would be outlined. This system is developed to address the limitations of Industry 4.0 and to be applicable in industrial settings. A case study is conducted to assess the applicability of this system. This research contributes to a greater understanding of Industry 4.0 applications within a structured Lean industrial setup.</p>

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The formulation and implementation of Kanban 4.0 for integrated lean digitalized industrial systems

  • Ismail Medhat,
  • Amr Nounou

摘要

This research explores the integration of Industry 4.0 (I4.0) and Lean Manufacturing, with the aim of bridging the gaps between theoretical advancements and practical industrial applications. Industry 4.0 offers a set of advanced technologies that can significantly enhance Lean Manufacturing methodologies, particularly in the area of digitalizing Lean tools. The formulation and implementation of Kanban 4.0 within the I4.0-Lean framework represent the core of this study, since Kanban serves as the center of information and data processing, as well as inventory and materials management. In this framework, Value Stream Map (VSM) icons such as Production Kanban, Supermarket, and Withdrawal Kanban are transformed into actionable push buttons, which are part of a novel Kanban 4.0 system design named “Central Digital Kanban Board”. This system integrates all processes into a single web-based solution. The actions of these push buttons are stored in the database, replacing the physical Kanban cards with digital ones, and enabling real-time calculation of Overall Equipment Effectiveness (OEE) for individual machines and integrated OEE for the entire system through digital dashboards. In addition, the actions of these push buttons result in the digitalization of the Value Stream Map (VSM 4.0), including real-time calculations of cycle, takt, changeover, and inventory times. Also, the inventory quantity, total production lead time, and value-added time are calculated to provide comprehensive real-time performance metrics for the system. To fully integrate the system within the I4.0-Lean framework, the information shared with Enterprise Resource Planning (ERP) would be outlined. This system is developed to address the limitations of Industry 4.0 and to be applicable in industrial settings. A case study is conducted to assess the applicability of this system. This research contributes to a greater understanding of Industry 4.0 applications within a structured Lean industrial setup.