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3D SIMULATION SOFTWARE
out with arrows that shows each process, manufacturers are likely to identify where improvements can be made. 3D simulation software can enable this stream to be visualised.
5. Reducing and preventing mistakes Mistakes result in wasted material, time and money, and while every mistake cannot be avoided, reducing them as much as possible is key to ensuring efficiency. One of the ways that this can be done is by installing robotics into the production line, and by using a robot simulation to refine the process, possible mistakes can be detected before they happen in the real world.
WHAT IS LEAN MANUFACTURING?
Visual Components outlines the top seven lean manufacturing principles that businesses can implement to improve their processes
is leading manufacturers to take every step available to bring costs down. Lean manufacturing, otherwise known as lean production, six sigma, or kaizen, revolves around the optimisation of the manufacturing process. Specifically, this means greater efficiency, faster processes and higher consistency, plus production at a higher level of precision. While innovative, it’s a concept that’s existed for over a century, being adopted in Henry Ford’s car production line in the United States, and was widely used in Japanese manufacturing thereafter. To truly understand and adopt lean
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manufacturing processes, it’s critical for manufacturers to understand the seven major principles behind the philosophy.
1. Elimination of waste Reducing waste is critical to lessening the environmental impact of the manufacturing process and enable cost savings. By using 3D simulation software to simulate a planned component machining system for example, manufacturers can identify where equipment can be removed from the real device without impacting on its performance.
2. Valuing the human element Lean manufacturing places as much focus on employees as it does machinery. It’s critical for leaders to ensure that staff aren’t overworked, made accountable for
48 APRIL 2022 | PROCESS & CONTROL
ith the UK being the ninth largest manufacturing nation in the world, it’s a highly competitive sector that
successes and failures and have clear visibility of what their tasks achieve. The most optimised technology doesn’t count for anything if employees are undervalued and unappreciated. Again, 3D simulation software can be used to keep staff safe, such as accounting for social distancing during the Covid-19 pandemic.
3. Seeking perfection Continually looking to improve the manufacturing process also means a continuous desire for perfection, and places improvement at the heart of the organisation’s culture. Lean manufacturing revolves around constant evolution, and 3D simulation software can continually refine improvements before applying them in the real world.
4. Mapping the value stream The value stream details how a product is created in the facility, or in other words, the map that tracks raw material on its journey to becoming the final product. By laying this map
6. Identifying loss of value The elements that make up value in the manufacturing process are lead times, price points, colour, material properties and material used, functional and geometric requirements of the product and repeatability, accuracy and precision of parts. Simulation software can enable manufacturers to see if there are any extra process steps or unnecessary features that will hurt that value.
7. Automatically finding defects In the case where mistakes can’t be prevented, there should be processes in place to achieve automatic detection. This could involve the identification and removal of any defective material. For example, if ferrous metal contamination is ruining the product, then the installation of strong magnets along the line will automatically find defects, while smart sensors or cameras could be installed to also achieve the same effect. Following these seven principles will not
only allow manufacturers to achieve higher levels of efficiency and optimisation, but will also open up new opportunities in the manufacturing process. One of these is just- in-time manufacturing. Lean processes mean manufacturers are better placed to produce goods based solely on demand, helping to reduce capital and money involved in the production. While this may mean longer lead times for customers, the potential for wasted products can be eradicated. Ultimately, lean manufacturing enables a
highly efficient, environmentally-friendly and competitive manufacturing process using emerging technologies such as automation and simulation. With this, manufacturers are better able to design a factory of the future that’s aligned with the digitised ideals of Industry 4.0, and helps them adapt to a rapidly changing sector.
Visual Components
www.visualcomponents.com
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