A Quantified Analysis of Lean First Then Automate for a Synergetic Effect

ABSTRACT Lean manufacturing has become a buzzword for the past few years due to its capability to reduce waste and make the system more efficient. To meet the numerous demands of consumers, companies are moving toward Industry 4.0, which can be accomplished through automation. Prior research demonstrated a conceptual integration of lean tools' effects into automation, but it lacked a quantitative analysis. The purpose of this study is to ascertain the effects of implementing lean tools prior to automation. To get real‐time data for the analysis of applying lean and automation, an empirical study was conducted on a manufacturing line. Using ARENA simulation software, four distinct simulation models were created using the data: the current assembly line model, the model with a lean tool (Inline Quality Check), the model with only automation, and the model with lean applied first and automation applied later. The productivity of the assembly line is used to compare the results. The comparative analysis demonstrated that applying lean tools prior to automation increases productivity in automated lines. This study could assist businesses understand that, before implementing automation, they should use lean technologies to improve system efficiency. An effective system can become considerably more efficient by being automated.