There’s been a lot of debate about whether the principles of lean and automation are at odds with each other. Some lean devotees have gone so far as to call lean automation an oxymoron, stating that manual systems and operations are usually, if not always, a better solution in terms of increasing productivity, adding value and eliminating waste. But is it possible for automated systems to be truly lean?
The answer is yes, if automated solutions are implemented the right way – and, more importantly, by the right people with the right skills and training. With the proper testing, deployment and supervision, these two concepts don’t have to be in conflict.
Automation with a human touch
The idea of lean automation comes right from the source of the entire philosophy of lean: the Toyota Production System (TPS). Interestingly, the word for this lean principle in Japanese, “jidoka,” connotes a human element in automated systems – sometimes referred to as “automation with a human touch.”
In keeping with “jidoka,” machines are designed to stop all processes when abnormalities are detected. This prevents defective products from making it all the way through the production line, allowing workers to fix the problem immediately and prevent it from happening in the future by correcting the root cause. The automated equipment frees up workers from having to constantly monitor a machine. Instead, their attention is focused on what to do after automated systems alert them to a problem.
Stages between manual operations and automation
At the moment, automated systems can detect flaws but typically can’t correct them automatically – or at least not cost effectively. In other words, there are stages in between an exclusively manual operation and a fully automated one. Some human input is essential – and this is how automation can be consistent with lean principles.
At PhaseAlpha, we believe these two can co-exist by developing custom software in areas that are truly eligible for automation.