- Material and energy balances
- integrated cost accounting
- Material flow cost accounting according to ISO 14051
How does Umberto support lean production?
Umberto, our lean production software, helps you recognize the most important relationships and potentials for improvement at a glance. Umberto supports your lean production goals through:
- comprehensive analysis and visualization of the value and process chains
- efficient use of raw and operational materials
- consistent avoidance of waste in the manufacturing process
Would you like to discuss how Umberto can help you get on the right track towards lean production?
Why lean production is important
Lean production is characterized by identifying and eliminating inefficiencies. Doing so will continuously add value to your production system. Specifically, it means eliminating overproduction , defective products, unnecessary processing, excess use of resources, and unnecessary transportation.
Which software is best suited for your lean production needs?
- Material and energy balances
- integrated cost accounting
- supports energy management according to ISO 50001 and DIN EN 16247
- Ecological efficiency analyses according to ISO 14045
- LCAs according to ISO 14040/44
- Environmental and cost analysis using a single model
What are the benefits of focusing on material and energy use in lean production?
Many lean production measures require no or only a few basic technical changes in the existing processes and facilities. Often, process related waste generated by the production system goes unquestioned. Just by determining the real cost of these losses with the help of Umberto's material flow cost accounting tool, line operators gain a new awareness of process related waste and gain an incentive to avoid such losses, with no expensive additional adjustments.
More benefits of focusing on material and energy use:
- a comprehensive system understanding
- optimized added value
- increased system efficiency
- cost savings through decreased use of energy and materials
- identification of the true cost of materials loss
- reduction of waste
- improved product quality
Productivity is no coincidence
Efficiency engineering is today's process engineering
When it comes to implementing improvements and changes directly at the processing and facility level, process engineers are at the forefront. They also play a critical role during the design of new installations.
Software-driven process simulators are often used to facilitate planning. By analyzing individual product processes, such simulations create an improved and detailed understanding of each individual step in the overall production system.
Unfortunately, this often leads to losing track of how all the different material, energy and cost streams are interrelated on a systems-wide scale. Umberto is able to precisely close this gap. It allows the optimization of the overall system and avoids situations where individual processes are improved, but at the expense of the entire operation.
The most prominent aspects, for which Umberto determines optimization potentials are:
- energy and heat recovery
- recycling of expensive auxiliary materials, especially if high disposal costs are involved
- in-house recycling
- reduction of internal process cycling through waste reduction thus increasing production capacity
Umberto – a new take on lean production
What is lean management?
The term 'lean management' applies to principles and methods for a more efficient design of the entire industrial goods value chain. It especially applies to mass production and manufacturing, where the principles of lean design are most important. Lean managers often interpret the term in two ways: as the optimization of management processes, and as the continuous improvement of throughput efficiency and product quality (continuous improvement process, or CIP).
When introducing lean management, a typical first step is to visualize the entire value-adding processes. Quite often this is done by hanging a large sheet of paper on the wall and using it to sketch out an analysis of the entire value stream.
By using Umberto as a lean production software tool, this visualization exercise turns into a dynamic computing system. The software takes into account all material production factors for the entire value chain. When analyzing improvement potentials, other lean production tools focus on factors such as processing time, production sequence, and stock-keeping. But in tracking the seven types of waste, Umberto also quantifies material movements, inventories, transitions, transport distances, and downstream impacts to visualize untapped potential and to identify inefficiencies. Different scenarios let the user compare and weigh alternative ideas for process improvement. Umberto's focus is not directed toward visualizations of business practices related to management.
Open information and feedback are another aspect of lean management. Any of the staff's know-how and skills that are not utilized to improve the overall production process is considered a waste. You therefore need a common base that bundles this knowledge and communicates it effectively through a common understanding of the systems involved. Umberto can create this base by visualizing easy-to-understand models of all flows and processes along the entire value chain. This creates full transparency for both material and energy flows as well as the associated costs. The value added by one process step to the next becomes readily apparent.
What is lean production?
Lean production is part of lean management, but is also a specific approach. It focuses on the production of goods based on achieving a minimum of input. One of the core principles of lean production is continuous processing of materials, from the start of production until the completion of the product. It allows no buffers - or “overproduction” - between individual phases in the production process. When introducing lean production to an operation, an important first step in making the changeover is a value stream mapping (VSM).
Expansion of the lean production concept
In addition to value stream mapping, a material flow analysis should be performed with the help of Umberto. The combination of both the value stream and material flow analyses creates unique cost transparency. This transparency not only applies to the entire system, but also to each individual product – which is especially useful in complex multi-product systems. Another benefit of this approach is that costs, which usually are only accounted for across-the-board (think “fixed costs”), are now identifiable in detail - auxiliary and operational materials use, for example, and breakdowns of where energy is consumed, etc. As a result, this analysis goes beyond the classic lean production concept since it not only calculates the cost for defective products, but also the costs from any leftover materials, waste, or resulting emissions (see material flow cost accounting). The tools of the Umberto NXT product family optimally support and expand the lean production concept.