How lean can help shaping the future – compact factories

The factory of the future has to comply with several constraints, among which the energy efficiency and respect of environment, the latter meaning nature as well as neighborhood.

Factories of the future will probably be close to housing areas, not only because in some areas space is scarce but because commuting is a major source of waste and annoyance.

Factory leanness is directly and positively correlated to its compactness. The more compact the factory the less travel distance within. Distance induces transportation and motion wastes. The shorter the distance, the less these types of waste.

The shorter the distance, the shorter the lead time hopefully.

Compact factories do not allow large inventories. I remember Japanese factories and the mini trucks; if you cannot store, deliver more often! (not sure about energy efficiency and environment friendliness of the trucks milk runs though).

Factories of the future will be built in flow-logic, unlike their centuries-old ancestors in which flows are just nightmares. Actual greenfields easily supercede brownfields and elder facilities on this point.

Best would be scalable units that can be plugged one to another, like plug-and-play shelters having some commodities ducts and cables pre-installed/pre-wired. Among them, Smart Industry or Industrie 4.0 (Europe) standard industrial buses for connecting anything out of the Internet of Things (IoT).

Such shelters could be specialized, like holding 3D printers, laser cutters or 3D scanners ready to use. They could be rented on-demand, installed, connected and used for some period and reused somewhere else after that. A kind of Rent-a-factory..!

Compact factories (in volume) need less heating and air conditioning and less artificial light. Industrial compressed air – if still in use – or other gases need less piping and volume in pipes in compact factory, less compressor units and power.
Air leaks in bigger facilities often require an additional compressor for compensation.
All good points for the sake of energy efficiency.

Most of the principles listed above are lessons learnt from lean experiences with existing factories. In such old-style factories, the improvements are often limited by physical, building construction constraints. Taking these lessons learnt into account is a way lean can help shaping the future.

 Bandeau_CH11View Christian HOHMANN's profile on LinkedIn

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