Chapter 24: Frameworks: Lean, Six Sigma, TPM, Industry 4.0 Reference Models

Summary: Operational excellence frameworks provide common methods and language to reduce waste, variation, and downtime. When combined with Industry 4.0 reference models, they guide technology choices that amplify process improvements. North American manufacturers succeed when digital initiatives are mapped to Lean, Six Sigma, and TPM goals—and measured accordingly. This chapter aligns improvement frameworks with modern architectures and data practices.

Context and Scope: Relevant to continuous improvement leaders, plant engineers, and IT architects. Bridges CI initiatives with MES/SCADA/ERP/PLM and data platforms.

Key Concepts:

Lean: Eliminate waste (muda) and optimize flow (e.g., SMED, Kanban, 5S).
Six Sigma: Reduce variation using DMAIC and statistical methods.
TPM: Maximize equipment effectiveness via operator care and planned maintenance.
Industry 4.0: Data, connectivity, and automation enabling CI at scale.

Standards and Regulations:

ISA-95 models for equipment and data structuring.
ISO 9001 for process documentation and control.
ISO 50001 for energy-focused improvements.

Architecture/Processes:

Map CI objectives to system capabilities (e.g., SMED → digital work instructions; TPM → condition monitoring).
Event-driven triggers from telemetry to action in MES/CMMS/QMS.
Tiered visual management with standardized KPI packs.

Data and Interoperability:

Define canonical data for OEE, changeovers, quality checks, and maintenance.
Collect high-frequency telemetry with context for root cause analysis.
Close the loop with PLM for design-driven improvements.

Security and Compliance:

Govern access to CI data and improvement logs.
Maintain audit trails of changes to process settings and instructions.
Secure OT networks supporting continuous improvement tooling.

KPIs and Metrics:

OEE and component metrics (availability, performance, quality).
Changeover Time, Setup Yield, and Line Balance efficiency.
FPY, Defects per Million Opportunities (DPMO).
Planned Maintenance % and Schedule Compliance.
Energy intensity improvements tied to CI.

Implementation Checklist:

Establish a CI governance board with IT/OT representation.
Prioritize CI projects; align to measurable KPIs and ROI.
Instrument lines; standardize downtime and quality data.
Deploy digital work instructions and SPC where needed.
Integrate CMMS with condition monitoring and MES.
Review progress in tier meetings; update standard work.

Common Pitfalls and Mitigations:

Tools before methods: Start with CI goals; then select tech.
Siloed efforts: Use cross-functional teams and shared KPIs.
Data without action: Integrate alerts with MES/QMS/CMMS workflows.
One-off wins: Template and scale successful practices.