Axiomatic model for Lean 5.0 manufacturing systems design: application in additive manufacturing systems

Purpose The purpose of this paper is to introduce the Lean 5.0 concept and the proactive integration of its requirements to design waste-free, sustainable, resilient and human-centered manufacturing systems. Design/methodology/approach Using the axiomatic design (AD) method, this paper proposes a generalized proactive Lean 5.0 model. The model presents guidelines to the structured integration of Lean requirements during the system design phase within the context of I5.0. It is built upon three main facets: “Design a Sustainable Lean Manufacturing System,” “Design a Resilient Lean Manufacturing System” and “Design a Human-Centric Lean Manufacturing System.” The results of the axiomatic model was specifically applied to an additive manufacturing system (AMS) to demonstrate its effectiveness. Findings A framework and a novel roadmap using AD for the comprehensive design of Lean 5.0 manufacturing systems were developed. This roadmap outlines a set of generalized performance parameters that support the integration of Lean in alignment with I5.0 principles. These parameters are adaptable to a variety of industrial contexts. The application of this roadmap to an AMS demonstrated reductions in impression time, material consumption and post-processing complexity, along with improvements in part quality and the elimination of human involvement in dangerous and repetitive tasks. Practical implications The proposed Lean 5.0 axiomatic model can be used by companies to design future manufacturing systems that integrate Lean and I5.0 principles, ensuring performance goals are met from the beginning and eliminating the need for later Lean interventions. Originality/value The absence of prior work attempting to design systems that combine and integrate Lean with the fundamental principles of I5.0 using AD highlights the significance of this study. It serves as a foundational proposal that can be further developed to provide domain-specific details for various industries.