Since the inception of lean, there has been debate over technology’s role. Applications and controllers can help to automate processes, but lean proponents always warn that automating the wrong processes can be detrimental to the ultimate goal of reducing waste.
Before introducing any technology into the mix, lean experts say, companies should go through some lean exercises, starting with value stream mapping of operations, or creating a visual rendering of processes, including how information and material flow, and then identifying where there is waste. Once the up-front lean legwork has been done and the non-value-add areas are identified and removed, software can be used to automate specific processes, such as how information flows or is accessed, heightening the overall lean effect.
“Lean is about people and processes, but software is a facilitator,” says Mark Symonds, CEO of Plex Systems, a provider of on-demand enterprise resource planning (ERP) software.
Indeed, operational excellence, which is how many manufacturers define their lean initiatives these days, often requires technology tools to automate the many processes that make up a modern manufacturing company. In fact, in a Managing Automation Reader Poll, nearly 50% of respondents said they are turning to ERP as part of their lean strategy. The poll also showed that 31.7% are using warehouse management software and 17% are tapping into business intelligence technology to accelerate their lean efforts. Regardless of the applications, the key, once again, is to make sure the right process is automated, experts say.