Controls News 13
Main theme: Lean automation
The lean story
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Lean is one of three guiding principles that we sincerely intend to
uphold and pursue in the long term.
Main theme: Lean automation | Definition
Lean automation
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The introduction of lean production leads to a significant increase
in productivity, flexibility and speed. Stresses and strains in the
factory are simultaneously reduced.
Main theme: Lean automation | Processes
Lean = maximum value and efficiency instead
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of a minimum purchase price
With lean production, employees are a key element in generating
value, not a mere cost factor. The primary aim is to use available
resources to create maximum value and quality.
Main theme: Lean automation | Structure
The lean added value chain
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It takes a lot more than a single purchase and delivery transaction
before operational automation systems start to generate value for
their owners. Systems are neither consumables nor commodities.
Main theme: Lean automation | Technology
Lean Technology = PLC +Web + IT
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The «magic» formula incorporates the best of all worlds into each
automation device. Consequently, automation systems built in this
way are sleeker and lighter: leaner.
Main theme: Lean Automation | Products
Lean products Examples
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Automation should mean that twice the amount of work can
be done with half the number of qualified personnel, at no extra
cost.
Main theme: Experiences with Lean
The path to lean: Personal experiences with lean
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How did the author find his journey towards lean? What did
Saia-Burgess go through as a company in the changeover process
and what experiences and perspectives resulted from it?
Main theme: CIP does not result in lean | Guest contribution
Kaizen in lean companies
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«
Radical democratic» innovation process with ultimate «radical
consequences» implementation of developed standards.
Focus issue: With Saia®S-Energy, efficiency makes everyone happy
Lean energy monitoring and control is the basis for
secure and economical energy efficiency gains
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There is a great temptation to knock the issue on the head with a
single, all-encompassing, all-powerful software solution.
Focus issue: The new class of devices combines strengths, eliminates weakness
Saia®PCDs become Saia® function PCDs
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Why a new class of device? «Lean Automation» aims to provide
twice as much automation at no extra cost and with half the
number of qualified personnel. This is feasible only if there are new
types of automation systems.
Focus issue: Management level for lean automation
Control/management level with Saia®PCD:
«
doesn’t work» almost doesn’t exist!
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With Saia®PCD automation stations, the whole management level can
be custom designed. Anything that serves the customer is possible
–
from small-scale equipment to widely distributed equipment.
Focus issue: Cost-benefit of lean technology for the operator
Cost-benefit analyses
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This analysis shows the additional costs incurred by the
manufacturer – and the added benefit for the user –
when automation systems are designed consistently for long
life cycles.
Focus issue: Saia®S-Engineering = Lean Engineering
The path to automation solutions:
simple, secure and always open
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S-Engineering describes the basic properties and methods by
which Saia creates hardware and software products quickly and
reliably for efficient automation solutions.
Focus issue: S-Energy as the basis for attractive service provision
Service provision with S-Energy: Increase energy
efficiency and earn good money at the same time
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Automation professionals are now entering a new field of activity. As a
result of the events in Fukushima, the pressure to reduce energy
consumption has increased dramatically. What’s needed are solutions
and services that make more effective use of existing resources (...)
Reference projects
Summaries of 12 interesting projects
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Lean automation technology in applications.
Reference projects: 34 km Lötschberg Base Tunnel
The route from «non-Lean» to «Lean»
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The mistakes from the construction phase are being corrected.
After 2 years of operation, the railway company BLS realised the
project «New tunnel control technology».
Reference projects: Energy efficiency at automotive supplier in China
Saia® S-Energy technology in harsh Chinese industry 54
Energy management in harsh industrial environment –
Johnson Electric manages to reduce the energy requirements
using brains and smart ideas. High investment? Wrong!
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