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Waste reduction and efficiency improvement are the main objectives of lean systems engineering.

Lean systems engineering is developed from a set of tools and techniques and can fit nicely in cost focus or cost leadership competitive advantage strategies. Studies prove that lean systems engineering principles provide a good source of competitive advantage and is applicable for many industries.

Some feel the biggest threat in implementing lean is lack of understanding the concept, but those who engage consultants were more successful.

The real-time data and communication between people, machines, and lean systems provide a holistic view of production and empower frontline workers to make adjustments in real time. BCG reports that companies that combine lean and industry 4.0 can achieve a 40% cost reduction.

Analysts recommend that manufacturers who want to go lean should first design a digital process that will collect data. The design process in lean 4.0 is ongoing. Benchmarking data to gain insight into the present state may uncover flaws in the existing process.

This is why flexible development matters for manufacturers. Outside of having a data-driven, clear approach, manufacturers should start where there are a clear use case and benefit. This approach gives a quantifiable measure of if the implementation is a success or not.

Up next is the initial test drive into production. Test and collect data. Make sure you’re collecting data that gives insights into which elements need to adjust to make the test successful. If operators are struggling to adapt to the new technology, seek to understand why and if this is a long or short term challenge. To uncover this challenge, you’ll need to track productivity in a process by the operator.

Finally, iterate and scale. With lean systems engineering, the testing never really stops. The technology enables continuous improvement, but the iteration is what makes the process truly continuous. Apply learnings from test to other lines, and apply conceptual learnings to other areas for expanded testing at the pilot plant.

Want to learn more? Tonex offers Lean Systems Engineering Training, a 3-day course that covers how and when systems engineering can most effectively and efficiently add value throughout a program’s lifecycle (SDLC).

Lean Thinking (Lean) is the dynamic, knowledge driven and customer-focused process to eliminate waste and to create values.

With SE and Lean, organizations can create a superior systems engineering process or Lean Systems Engineering. This course provides Lean Enablers for Managing Engineering Programs.

For more information, questions, comments, contact us.

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