conversion cost reduction of manufacturers deploying lean 4.0- over five to ten years

In traditional Lean , tools like JIT and Kanban rely on precise scheduling and human oversight . In Lean 4.0 , these tools are supercharged with tech :

• Just-in-Time 4.0 uses IoT and Big Data to track inventory and predict production needs , reducing downtime and waste

• Kanban 4.0 moves from physical cards to digital systems , allowing real-time adjustments based on production flow and customer demands

• Poka-Yoke 4.0 integrates with sensors and AR to guide workers through error-proof processes visually .

These synergies enable greater waste minimisation , improved supply chain flexibility , and seamless integration across processes , devices , and people .

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