Lean thinking and simulation software are the right tools for waste-reduction

Moves to reduce waste are well underway within most manufacturing businesses, even if there is still a long way to go.

Alongside construction, manufacturing contributes 6.22 billion tonnes annually to the UK’s greenhouse gas emissions. From errors on the production line to inefficient configuration of robots, there are still numerous opportunities for waste elimination that organisations have yet to grasp. To enhance manufacturing’s environmental credentials, businesses must prioritise efficiency in all facets of their operations without delay.

Reducing waste on the factory floor is not just about technology, it requires a major change in mindset. Lean manufacturing is an important concept, focusing on improving efficiency, speeding up processes, and ensuring consistency. This methodology was introduced in the early 20th century, and because it has proved to be highly effective, remains integral to car production at Toyota. The company exemplifies lean manufacturing by producing only what is needed, when it is needed, and in the required quantities. Adopting such practices can significantly help UK manufacturers minimise waste and improve overall operational efficiency.

The digital approach to getting leaner

Eliminating waste is a fundamental principle of lean manufacturing, and simulation software has emerged as one of the primary tools that help businesses achieve big advances towards this goal. By running a precise 3D simulation of a planned component machining system, manufacturers can determine whether robots and items can move efficiently and complete their tasks. The software is ruthless in identifying any process bottlenecks and reveals unnecessary equipment that businesses should eliminate. Armed with these insights, the organisation not only removes surplus materials and equipment but also avoids the associated purchase costs, leading to significant savings and improved efficiency.

Simulation software also reduces wasted time by ironing out inefficiencies in the way AGVs (automated guided vehicles) move materials around a warehouse or factory floor. The solution will identify potential gains more rapidly than unassisted humans, enabling businesses to streamline processes and cut down on waste more effectively.

Improving robot operations

Errors in a production process lead to wasted materials, time, and money. One common cause is the incorrect programming of robots used for tasks such as welding, cutting, or spraying. For instance, if a robot fails to move a welding torch in the correct circular 3D arc around a metal workpiece, the material may very well need to be discarded.

Robot offline programming (OLP) addresses this problem by allowing factory staff to create a highly accurate digital model of a specific robot and its work cell. This simulation fully replicates the robot's movements and workflows. By validating a robot's actions before actual production, users can refine the process to ensure high accuracy and eliminate potential errors. Implementing OLP enables manufacturers to harness the precision and repeatability of robotic processes, significantly reducing the likelihood of mistakes and, consequently, waste.

If organisations also want to include employee travel in their carbon footprint calculations, simulation software enables them to reduce journeys. Staff can collaborate with factory-based colleagues from home, sharing detailed layout plans without the need for physical presence, reducing the organisation’s overall emissions profile.

Slashing waste through better management

A rethink about waste management to introduce greater efficiency is now essential for manufacturers aiming to shrink their environmental footprint. Lean manufacturing, with its laser focus on waste elimination, empowers businesses to fine-tune production processes. By harnessing advanced simulation software and OLP, manufacturers can achieve unprecedented precision, slashing waste and costs while saving time. As the push for sustainability accelerates, embracing these technologies isn't just smart—it's essential for staying ahead in a competitive market.