Lean manufacturing and automation

Lean manufacturing and automation goes hand in hand for most of the manufacturers. Although lean dose not mean automation, automation can be a useful tool in lean processes. Automation will bring higher quality, repeatability, and consistency to the particular process. It is important to look for the possibilities of automation in a lean environment. So the question is what can we automate? What will help automation?

Process which,

1. Are repeated over and over again
2. In every cycle there is no decision making is required
3. Are with same inputs and outputs

Can be automated. But the possibility of automation depends upon the technical feasibility, cost effectiveness and other interests of the organization. It is very important to understand, if the process doesn’t require any human intervention like subjective decision making (Ex: Color and shades for a car) in theory that process can be automated. 

So how can we make processes which can be automated? One of the most important concepts of lean manufacturing, standardization makes it possible to automate the processes. Standard processes define a way of operation. There is almost no requirement of human intervention to make the process happen. If it goes wrong, humans can analyze to find root causes and cure the root cause to solve the problem. 

Lean provides a perfect ground for automation. But the decision to automate the process needs careful analysis. The technical feasibility, cost effectiveness of automation, environmental and social factors can influence the decision on automation. 

In a concluding note, automation should not be looked as a way of reducing the head count. Lean manufacturing is built on respecting human resource. By removing that pillar or by weakening it, you can not become a lean manufacturer. Automation is to liberate people from their repeated tiring work, not to remove them from their jobs.