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To offer lean design and assembly principles with a focus on “monozukuri,” meaning sustainable, environmentally friendly factories and products with simultaneously integrated product and process designs.

Based on extensive study of products, processes and factories, 18 “monozukuri‐focused” product, process, factory design and management principles are explained by the author.

The rule‐based approach to designing lean, sustainable, “monozukuri‐focused” flexible products, processes, production systems and factories will reduce waste at all levels, and create new opportunities for satisfying dynamically changing market needs.

Reveals 18 lean design and assembly line design and management principles with some practical industrial examples.

This paper sets out to present how manufacturing system controllers can be an important part of a total system of real‐time manufacturing metrics data gathering and analysis as well as part of the quality control, product tracking and history documentation procedures.

The paper presents an overview of the GE Fanuc Proficy Production Management Solutions software system and illustrates some of the applications that can be applied in the factory.

Users can achieve significant benefits such as cost reduction, quality improvement, reduced product recalls and more easily meet government regulations by applying manufacturing metrics software to production applications.

Production controllers can be an important part of the process to reduce costs and improve quality as operations metrics move on to the factory floor.

Users now have a new avenue to better capture and analyze production information in real time.