Lean Manufacturing Meets Industrial Automation: From Waste to Worth with Lights-Out Machines
Lean Manufacturing Meets Industrial Automation: From Waste to Worth with Lights-Out Machines.
Lean manufacturing isn’t just a methodology – it’s a mindset. At Position Automation, we bring this philosophy to life through smart industrial automation systems that eliminate inefficiencies and unlock real productivity.
Eliminating All 8 Classic Wastes
Lean identifies eight types of waste. Our machines are engineered to eliminate every single one:
- Transportation: Automated conveyors and integrated handling reduce unnecessary movement.
- Inventory: Pull-based production and Kanban workflows maintain optimal stock levels.
- Motion: Smart positioning and automated clamping reduce operator strain.
- Waiting: Continuous flow design and lights out machine capabilities minimise idle time.
- Overproduction: CNC-driven precision ensures output matches demand.
- Overprocessing: Intelligent design removes redundant steps.
- Defects: Sensors and repeatable automation reduce human error.
- Unused Skills: Automation frees skilled workers for higher-value tasks.
Lights-Out Manufacturing: Automation That Never Sleeps
One of the most powerful outcomes of lean automation is lights-out manufacturing, systems that run unattended, even overnight. Our machines are built for:
- Bulk processing of long profiles
- Automatic feeding, clamping, and cutting
- Intelligent ejection and repositioning
- Minimal operator intervention
This reduces labour costs while increasing uptime, consistency, and ROI.
Case Study: From 35 Minutes to Just Minutes
A client needed multiple holes drilled into box sections of varying sizes. Previously, this took over 35 minutes per section manually. With our custom machine:
- The profile is automatically fed, cut, and drilled
- The process is completed in a fraction of the time
- One operator was freed up entirely
- ROI was achieved in under 6 months
This is lean in action – real savings, real speed, real results.
Lean Tools Built into Every System
Our machines support key lean tools:
- 5S: Organised, clean, and efficient workspaces
- Kanban: Visual scheduling and inventory control
- One-Piece Flow: Continuous, sequential processing
- Line Manufacturing: Modular, scalable production lines
- Kaizen: Continuous improvement through data and feedback
Lean isn’t a one-time fix, it’s a culture of continuous improvement. At Position Automation, we’re committed to helping manufacturers eliminate waste, improve quality, and scale smarter.
