Digitization to Support Lean and Optimization in High-Mix Low-Volume Environment

This chapter presents a case study of production management at Manitowoc’s Moulins site, which involves significant complexity due to its High-Mix Low-Volume (HMLV) environment, the rigidity of its conveyor system, and recurring disruptions such as supply delays and quality issues. Although lean practices—particularly Heijunka for production leveling—were initially implemented to support sequencing, their impact remained limited in the absence of digital integration. Manual data handling, delayed feedback from the shop floor, and lack of real-time visibility hindered both planning accuracy and sequence compliance. To overcome these constraints, Manitowoc internally developed an integrated Industry 4.0–oriented solution: the easy planning system. This in-house tool combines lean principles, intelligent digitization, and optimization techniques. It automates data integration from ERP and Excel sources, provides real-time feedback through IoT-enabled tools, and supports decentralized yet coordinated decision-making. Sequencing was enhanced by embedding operational constraints into digital models, then further optimized using local search algorithms. Complementary digital lean practices—such as visual management, standardized work, and real-time performance dashboards—reinforced operator engagement and improved compliance. This interconnected framework enabled a more robust, responsive, and cost-effective production system, ultimately increasing the service rate. While the solution is tailored to Manitowoc’s specific context, it offers valuable insights for broader application in similar HMLV manufacturing environments seeking scalable Industry 4.0 transformation.