top of page

Lean AI: Lean Production Meets Artificial Intelligence in Manufacturing

Updated: Nov 15, 2023

Going Lean

Lean is defined as a set of management practices to improve efficiency and effectiveness by eliminating waste. The core principle of lean is to reduce and eliminate non-value-adding activities and waste.

Lean manufacturing is a series of principles and techniques to help improve performance in factories, production lines and machines by eliminating as much waste as possible. Specifically, it maximizes delivered value through continuous improvement and minimal waste. In other words, lean production is about “doing more with less.”

Companies are always limited by the number of resources they have, whether the number of people or the amount of money or materials needed in the manufacturing process. Lean manufacturing is also a process that focuses on eliminating waste to reduce costs in order to generate more profit.

Lean Manufacturing Requires AI

Like many great ideas, lean manufacturing is a seemingly simple idea that proves very difficult to implement. Its shortest definition is doing something in the most efficient, least wasteful way. Sounds easy, but things can get complicated when you get into the details of what entails waste and what’s expendable. That’s where AI comes in.

As AI continues to play a huge role in leading industries, it has also entered the world of manufacturing. The rise of Artificial Intelligence has introduced an innovative means to achieve such continuous improvements in production.

Studies suggest that 80% of manufacturers who had adopted AI realized a moderate (23%) or significant (57%) value increase over the last two years. Many of these companies have harvested data from IoT sensors, which AI can leverage to optimize processes and business results.

With the power of AI, process engineers can predict and prevent production waste by identifying areas of loss and prescribing focused actions that reduce product defects and inefficiencies.

Artificial intelligence allows greater connectivity between people, information, and machines therefore it improves how manufacturers optimize products and processes. Just as manufacturers have benefited from lean manufacturing, AI promises to be the next evolutionary step in productivity advancement.

Today’s Lean manufacturing systems drive the assembly-line staff experience, converting deep organizational knowledge into practical behavior and business value. Lean production and AI have the potential for innovation as company leaders incorporate staff experience into developing new roles and technology structures.

In manufacturing, the use of AI can optimize production without the need to invest in new and expensive manufacturing equipment. Researchers estimate that using AI solutions in manufacturing can significantly reduce yield loss. Combining AI with lean identifies optimal setpoints that reduce defects that previously required the technician and operator’s time to fix them. In addition, AI can conduct its observations, analyses, and resolutions without slowing or sacrificing production value. Furthermore, AI improves how it resolves problems as time goes on.

In Summary

Bringing AI into manufacturing is the smart way to achieve lean manufacturing. However, it all has to begin with getting your data into one location to be analyzed. Digitizing your manufacturing processes is an excellent place to start. With production record data, gathering cycle time data, analyzing each process, companies can get a holistic view of what’s going on in manufacturing and take steps to create a more efficient, lean manufacturing floor.

No matter your industry, the next industrial revolution is here. Khenda helps you get the most out of your next-generation technologies and your employees with unique AI solutions to your processes and best practices.

For more information on digitizing your company with Khenda, contact us at


Commenting has been turned off.
bottom of page