Smart Manufacturing: The Lean Six Sigma Way

Cover
Title Page
Contents
Foreword
Acknowledgments
About the Author
About the Contributors
Introduction
Chapter 1 Introduction to Industry 4.0 and Smart Manufacturing
	Introduction
	The First Industrial Revolution
	The Second Industrial Revolution
	The Third Industrial Revolution
	The Fourth Industrial Revolution
	The Major Components of Smart Manufacturing
		Lean and Six Sigma in the Age of Smart Manufacturing
		Improving Cybersecurity Using Smart Technology
		Smart Logistics
		Big Data for Small, Midsize, and Large Enterprises
		Industrial IoT Sensors
		Artificial Intelligence Machine Learning and Computer Vision
		Networking for Mobile-Edge Computing
		Additive Manufacturing and 3D Printing
		Robotics
		Smart Technology to Improve Life on the Factory Floor
	Summary: The Advantages of Smart Manufacturing
		Improved Quality and Safety
		Improved Margins
		Improved Cycle Times
		High Efficiency with Well-Defined Smart Factory Processes23
	Sample Questions
	Notes
Chapter 2 Lean Six Sigma in the Age of Smart Manufacturing
	Introduction
	The History of Lean – American Assembly Lines
	The History of Lean – Toyota Embraces Deming and Piggly Wiggly
	The Toyota Production System: The Birthplace of Lean
	Lean Empowers Employees, Treating Them with Respect
	Resilient Supply Chain Management: How Toyota Fared During the COVID-19 Pandemic
	The History of Six Sigma: Bill Smith and Jack Welch
	Six Sigma’s DMAIC Framework to Fix an Existing Process
	The DMAIC Framework Using Smart Technologies
	Six Sigma’s DMADV Framework to Design a New Process
	The Statistics Behind Six Sigma
	Six Sigma Professionals in the Age of Smart Manufacturing
	Six Sigma Project Charters and SMART Goals
	Lean and Six Sigma Uses of the Scientific Method
	Summary: Six Sigma’s Marriage to Lean
	Sample Questions
	Notes
Chapter 3 Continuous Improvement Tools for Smart Manufacturing
	Introduction
	Voice of the Customer in the Age of Smart Manufacturing
	Voice of the Customer Using Net Promoter Score
	Voice of the Customer Using the Delphi Technique
	Voice of the Customer Using the Kano Model
	Affinity Diagrams to Organize Many Ideas into Common Themes
	Critical to Quality to Convert the VOC to Measurable Objectives
	Types of Data
	Benchmarking
	Process Maps
	Types of Process Maps
	SIPOC
	Process Maps with Decision Points
	Process Maps with Swim Lanes
	Limited Data Collection and the Hawthorne Effect Impacting Process Mapping
	Value Stream Maps to Eliminate Waste
	Value-Added Activity versus Non-Value-Added Activity
	Root Cause Analysis Using a Fishbone Diagram and Risk Matrix
	Root Cause Analysis Using the Five Whys
	Changes Coming to Root Cause Analysis with Smart Technologies
	Pareto Chart
	Kanban Pull System
	Poka-Yoke to Error-Proof Processes and Products
	Five S
	Heijunka
	Plan-Do-Check-Act
	Kaizen
	Setup Time Reduction Using Single Minute Exchange of Dies
	Gage Repeatability and Reproducibility (Gage R&R)
	Failure Modes and Effects Analysis (FMEA) to Solve Complex Problems
	Pugh Matrix to Design New Processes and Products
	Quality Function Deployment (House of Quality)
		History of QFD
		Structure of the House of Quality Used in QFD
		Building a House of Quality
		Benefits of Using QFD
		Using QFD in Combination with the Pugh Matrix
		Smart Technologies to Automate QFD
	Summary
	Sample Questions
	Notes
Chapter 4 Improving Supply Chain Resiliency Using Smart Technologies
	Introduction
	Supply Chain Resilience
	Supply Chain Risk Heat Maps
	Supply Chain Mapping at a Macro and Micro Level
	Preferred Supplier Programs
	Bill of Material Risk Grading Tools
	Environmental Risk Solutions
	The Global Driver Shortage and Poor Utilization
	Vehicle Monitoring Tools
	Computer Vision Systems Using Smart Cameras
	Autonomous Trucks
	Supply Chain Resilency in a Post-COVID World
	Criticism and Defense of Lean Inventory Management
	Good Sourcing Strategies
	Supply Chain Stress Testing
	Summary
	Sample Questions
	Notes
Chapter 5 Improving Cybersecurity Using Smart Technology
	Introduction
	Trends Increasing the Risk of Manufacturing and Supply Chain Cyberattacks
		Globalization and Specialization
		Improved Security Within the Corporate Network
		Artificial Intelligence and the Internet of Things
		Software Supply Chain Compromises
		The Emergence of Cloud Computing and the Public Cloud
		Targeting Small Companies
	So Why Is Manufacturing and the Supply Chain an Attractive Target?
	Primary Motives Behind Manufacturing and Supply Chain Attacks
		Stealing Proprietary Information and Intellectual Property
		Financial Gain from Ransomware
		Political Motives
		Disruption of Operations
	Methods Used to Breach Target Systems
		Using a Third-Party Connection as a Means to Get to Your Network
		Using a Third-Party Connection as a Means to Get to Your Customers’ Information
		Tampering with Components or Products in the Manufacturing Process
		Tampering with Manufacturing Process Equipment
	What Are the Potential Costs of a Cyberattack?
	Protecting Against Cyberattacks
		Approaches to Mitigating Risk
		Developing Internal Processes and Controls
		Developing Secure Third-Party Relationships
	Summary
	Sample Questions
	Notes
Chapter 6 Improving Logistics Using Smart Technology
	Introduction: Why Logistics?
	Megatrends in Logistics That Impact Brands/Manufacturers
	The Different Expectation of Your Customer-by-Customer Type
	The Cost of Not Paying Attention to Logistics
	The Benefits of Making Logistics a Strategic Competency
	Steps to Make Logistics Your Competitive Advantage
	Why Technology Is So Important to Logistics
	Area 1: Insight/Planning/Monitoring
		Area 1, Use Case 1: Logistics Insight via Data Analytics
		Area 1, Use Case 2: Advanced Forecasting via Machine Learning and AI-Based Prediction
		Area 1, Use Case 3: Dynamic Decision-Making via Machine Learning and AI-Based Prediction with Real-Time Data and Blockchain
	Area 2: Task Execution
		Area 2, Use Case 1: Automation for Information Processing via Robotics Process Automation
		Area 2, Use Case 2: Automation for Physical Tasks via Robotics
		Area 2, Use Case 3: Autonomous Transportation via Autonomous Technologies
	Area 3: Exchanges and Collaborations
		Area 3, Use Case 1: Digital Freight Brokerage via Cloud Technologies
		Area 3, Use Case 2: Supply Chain Collaboration via Cloud Technologies
	Area 4: Safety, Security, and Compliance
		Area 4, Use Case 1: Global Trade Compliance via Cloud Technologies
	Summary
	Sample Questions
	Notes
Chapter 7 Big Data for Small, Midsize, and Large Operations
	Introduction
	Structured Data and Relational Databases
	Unstructured Data
	Why Manufacturing Needs Big Data Analytics
	The Four Levels of Data Analytics
	Descriptive Analytics – What Happened?
		The Five Phases of Descriptive Analytics
		The Value of Descriptive Analytics
	Diagnostic Analytics – Why Did It Happen?
	Predictive Analytics – What May Have Happened?
	Prescriptive Analytics – What Is the Best Next Step?
	Future of Big Data Analytics
	Data Science Tools
	Data Analytics Pipeline
		Collection
	The Benefits of Big Data for SMEs
	Big Data Tools for SMEs
	Problems SMEs Face in Adopting Big Data Analytics
	Best Practices in Data Analytics for SMEs
	Summary
	Sample Questions
	Notes
Chapter 8 Industrial Internet of Things (IIoT) Sensors
	Introduction
	PLCs
	Carnegie Mellon
	Consumer-Oriented IoT
	Webcams
	IIoT-Enabling Technologies
	IIoT Platform Building Blocks
	IIoT Sensors
	Application Areas for IIoT
	Industries Where IIoT Can and Does Play a Role
	Future Trends in IIoT
	Summary
	Sample Questions
	Notes
Chapter 9 Artificial Intelligence, Machine Learning, and Computer Vision
	Introduction
	History of AI and Computer Vision
	Understanding Machine Learning and Computer Vision
		Types of Machine Learning
		Common Computer Vision Tasks
		Building a Model
		Machine Learning Pipelines
	Issues with Artificial Intelligence
	Conclusion
	Sample Questions
	Notes
Chapter 10 Networking for Mobile Edge Computing
	Introduction
	Brief History of Networking
	Basic Networking Concepts, Architecture, and Capabilities
		Network Address Management
	Subnets
		Network Address Translation
		Ports
		Autoconfiguration of Networks
		Security and Reliability
		Introduction to the OSI Model
	Basic Wi-Fi Concepts, Architecture, and Capabilities
	Mobile Cell Phone Concepts, Architecture, and Capabilities
		Mobile Generations
		Cell Architectural Concepts
		Mobile Networking Security and Reliability
		Future Evolution of Mobile Networking
	IT and Telecommunications Networking Convergence
		Convergence of the Internet and Telephony
		Capabilities and Benefits of Mobile Edge Networking
	Summary
	Sample Questions
	References
	Popular Acronyms Used in Networking and Mobile Computing
	Notes
Chapter 11 Edge Computing
	Introduction: What Is Edge Computing?
	Benefits of Edge Computing
	Top Use Cases for the Edge in Smart Manufacturing
	The Data Challenge
	Deployment Challenges
	Solving Deployment Challenges with an Edge Computing Platform
	The Edge Computing Platform Landscape
	Edge-to-Cloud Computing
	How a Successful Edge Computing Rollout Works
		Step 1: Proof of Concept
		Step 2: Pilot
		Step 3: Scale
		Step 4: Optimize
	Summary
	Sample Questions
	Notes
Chapter 12 3D Printing and Additive Manufacturing
	Introduction
	History
		Early Stages of Additive Manufacturing
		1980s – The Emergence of the First AM Technologies
		1990s – Process and Innovation
		2000s – Development of New Applications
		AM Standards
	Additive Manufacturing Process
		VAT Photopolymerization
		Material Extrusion
		Material Jetting
		Binder Jetting
		Powder Bed Fusion
		Sheet Lamination
		Directed Energy Deposition
	Applications
		3D-Printed Electronic Devices
		3D Printing in Construction
		3D Bioprinting
		4D Printing
	Summary
	Sample Questions
	References
Chapter 13 Robotics
	Introduction
	Industrial Robots
	Manipulator
	Actuators
	Controllers
	End Effectors
	Types of Robots
	Robotics Timeline: 1961 to 2011
	Collaborative Robots
	The Outlook
	Sample Questions
	Bibliography
	Notes
Chapter 14 Improving Life on the Factory Floor with Smart Technology
	Introduction
	Life on the Factory Floor from 1700 to Today
	The Smart Manufacturing Factory Floor
	How AI Is Powering Smart Manufacturing
	Smart Manufacturing Is Optimizing Factory Processes
	Hurdles Faced in Implementing Smart Technologies
	Three Essential Job Types in Smart Manufacturing
		The Service Worker
		The Application Worker
		The Operator
	Three Types of Tools Needed in Smart Manufacturing
	Smart Manufacturing Design Choices
	Summary
	Sample Questions
	Notes
Chapter 15 Growing the Roles for Women in Smart Manufacturing
	Introduction
	Women as Innovators
	Women Hold the Answers (Skills Where Women Excel)
	Women’s Inspiration
		Barrier One: Building a Math Identity
		Barrier Two: The Question of Race and Class
		Barrier Three: It’s Not Just Content; It’s Context, Too
	Companies Working to Overcome Barriers to Women’s Entry
	Programs to Develop STEM Skills for Women
	Growing the Role of Women in Smart Manufacturing
		Marketability
		Pay Inequality
	Maria Villamil’s Story
		How I Got into Manufacturing
		My Career at WET Design
		WET’s Use of Smart Technologies
	Deborah Walkup’s Story
	Summary
	Sample Questions
	Notes
Case Studies
	Case Study 1 Automating Visual Inspection Using Computer Vision
	Case Study 2 Bar Coding, the Most Ubiquitous and Most Critical IIoT Technology
	Case Study 3 Improving Safety with Computer Vision
	Case Study 4 COVID-19 Accelerates the Adoption of 3D Printing
	Case Study 5 How Mobile Apps Benefit Small to Midsize Enterprises
	Case Study 6 Using Factory-Floor Touch Screens to Improve Operations
	Case Study 7 Edge Computing to Improve Operations
	Case Study 8 Five Highly Dangerous Jobs That Robots Can Do Safely
	Answers to Sample Questions
	Links to Continuous Improvement Templates
Index
EULA