Ubisense Declares the Death of Lean Manufacturing: Why Real-Time Data is the New King in Automotive

For decades, lean manufacturing has been the guiding principle for automotive production. The concept of maximizing value while minimizing waste has driven countless efficiency improvements and cost savings. However, as the manufacturing landscape evolves, Ubisense believes it’s time to challenge the status quo. We’re declaring the death of traditional lean manufacturing. In its place, we propose a new king: real-time data.

The Changing Landscape of Automotive Manufacturing

The automotive industry is undergoing a rapid transformation. Traditional lean principles, while still valuable, are increasingly being outpaced by the capabilities of advanced digital technologies. The need for flexibility, agility, and real-time decision-making is more critical than ever, especially as supply chains become more complex and customer demands more varied.

The old lean approach of carefully orchestrated, fixed processes can often lack the adaptability needed in today’s fast-paced environment. This is where real-time data comes into play.

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Why Real-Time Data Outperforms Traditional Lean Techniques

Real-time data is redefining what it means to be “lean.” By providing instant, actionable insights into every aspect of production, real-time data allows manufacturers to respond to issues as they happen, rather than relying on historical data and periodic reviews. Systems like SmartSpace by Ubisense are designed to provide this level of insight and agility, enabling manufacturers to:

  • Optimize Production Schedules: With real-time data, schedules can be adjusted on the fly to accommodate changing conditions, reducing downtime and maximizing productivity.
  • Enhance Resource Allocation: Rather than following a fixed plan, manufacturers can use real-time insights to dynamically allocate resources where they are needed most.
  • Improve Quality Control: Immediate feedback allows for quick adjustments, reducing waste and defects.

According to Jeff Immelt, former CEO of GE, “If you went to bed last night as an industrial company, you’re going to wake up today as a software and analytics company.” This quote captures the urgency with which manufacturers must embrace digital transformation.

The Role of SmartSpace in Driving Real-Time Decision-Making

Ubisense’s SmartSpace platform provides the real-time visibility and spatial intelligence needed to enable this new paradigm. By integrating real-time location data, asset tracking, and intelligent orchestration, SmartSpace helps automotive manufacturers move beyond rigid, outdated lean practices.

Our clients have seen firsthand the benefits of moving to a real-time, data-driven model. One such client, a leading automotive manufacturer, reported a significant reduction in production lead times and an increase in overall efficiency after implementing SmartSpace. This is the power of real-time data in action.

Aston Martin

Rising customer expectations and increasingly complex configurations are driving automotive manufacturers to constantly improve operations.

Aston Martin, world renown for performance and precision engineering, turned to Ubisense in order to achieve complete, automated and adaptable monitoring of their offline production process.

At the Aston Martin plants in Gaydon, England, and St Athan, Wales, the Ubisense Real-Time Location System (RTLS) enhances control of rigorous offline finishing processes. From inspection through to repair and rework, analysis and optimization of each process step ensures production efficiency is maintained at all times.

Ubisense tags are attached to each car as they begin the testing and finishing stages. From that moment on, Ubisense allows production engineers to monitor each Aston Martin in real-time as it progresses through the facility, with alerts if a car deviates from a normal or planned progression.

Previously out-of-date and error-prone paper and spreadsheet-based reporting was replaced with automated, up-to-date insights. Offline teams are guided to prioritize vehicles and tasks to maximise resource utilization and reliably meet delivery schedules.

The Future of Automotive Manufacturing

We’re not saying that lean manufacturing doesn’t have its merits—it does. But as we look to the future, it’s clear that the automotive industry needs more than just lean principles. It needs real-time data, dynamic decision-making, and the ability to adapt instantly to new challenges.

At Ubisense, we are proud to lead this shift. With SmartSpace, we’re providing manufacturers with the tools they need to thrive in this new era of automotive production. The message is clear: Lean is no longer enough. Real-time is the future.

Ready to Make the Shift?

Discover how Ubisense and SmartSpace can help you transition from outdated lean practices to a dynamic, real-time data-driven model. Get in touch with us today to learn more.