Lean Management
Lean Management, also known as Lean Enterprise and Lean Manufacturing, is a management philosophy based on the Toyota Production System (TPS). The objective of Lean Thinking is to eliminate everything that does not add value from the customer's eyes.




What Is Lean Management?


Lean Management is a management philosophy based on the Toyota Production System (TPS). This management philosophy was coined "Lean" only in the 1990s. The objective of Lean Thinking is to eliminate everything that does not add value (i.e. "waste") from the customer's perspective.

The general approach to Lean is learn-by-doing and to foster a culture of continuous improvement. In a Lean organization, we develop a value stream for each service family, make the product or service flow, and then continuously improve our process as we manage towards perfection. To achieve this goal of managing to perfection, there is a vast range of Lean techniques and tools available, which have been established and tested with numerous case studies. Examples of Lean frameworks include Value Stream Mapping (VSM), 5S, Kanban, Kaizen, Poka Yoke, Gemba Walk, Hoshin Kanri, Plan-Do-Check-Act (PDCA), Root Cause Analysis (RCA), Heijunka, etc.

The Lean Enterprise system is built on 2 primary pillars:

There are numerous business and organizational benefits to adopting a Lean organization. Some of these benefits include improved customer satisfaction (both internal and external), improve qualify of products or services, improved employee productivity, reduced paperwork, reduced employee stress, and more engaged employees.

Value vs. Waste

A couple key concepts in Lean Thinking are that of "value" and "waste." Activities can be categorized into those that add value and those that don't. Value-added activities increase the form or function of the product or service. They are activities the client or customer is willing to pay for.

On the other hand, non-value activities do not add form or function or are not necessary. They do not benefit the client or customer. They are things that are not necessary to run the department. These activities, in Lean terms, are called waste.

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The goal of Lean is to eliminate this waste. In fact, Lean Management can be defined as a systematic method for the elimination of waste within a business process.

Waste can be categorized into 8 types:

  1. Over-production. Producing more than what the customer needs. Examples include creating reports that no one needs or making extra copies, exceeding scope of agreement, purchasing items before they are needed (e.g. items on sale), etc.
  1. Waiting. Employees waiting for another process or a machine/tool. Examples include waiting to be served, waiting for instructions/approvals/information, equipment/System downtime, etc.
  1. Rework. Reprocessing or correcting work. Examples include data entry errors, poor process controls, incorrect schedules and information, etc.
  1. Transportation. Moving product from one place to another. Examples include poor workplace organization, insufficient use of tele-/video-conferencing, double or triple handling, etc.
  1. Inventory. Building and storing extra services/products the customer has not ordered. Examples include e-mails waiting to be read, business documents waiting to be worked on, too many office supplies, etc.
  1. Motion. Extra physical/mental motion that doesn't add value. Examples include searching for information on internet/computer, handling paperwork, unnecessary motion due to poor ergonomics or office layout, etc.
  1. Over-processing. Adding excess value when the customer does not require it. Examples include repeated manual entry of data, excessive documentation, multiple formats for the same information, etc.
  1. Intellect. Not using employees to their full intellectual contribution. Examples include not engaging or listening to employees in finding solutions, lack of best practice sharing, mismatched work functions with skill sets, etc.

What Lean Management Is Not

These are concepts that Lean absolutely does not represent:

To better understand how Lean differs from conventional management philosophy, let's look at several examples comparing these schools of thought.

TRADITIONAL THINKING
LEAN THINKING
  • Large batches
  • Small batches
  • Low unit costs
  • Total system cost
  • Work at full capacity
  • Work at necessary capacity
  • Tight schedules
  • Flexible schedules
  • High inventories
  • Low inventories
  • High level of specialization
  • Cross-training
  • Long cycle times
  • Short cycle times
  • Lean Management Model

    The Lean Management Model aligns all 5 pillars of Lean under one "Lean" umbrella:

    This article provides a very rudimentary introduction to Lean Management. To develop a more in depth understanding, we suggest downloading a free copy of the 32-slide Introduction to Lean Management presentation and consulting the business training guides below.

    Source: Lean Thinking 101, Eliminate Waste, Create Value, Operational Excellence Consulting [source material]




    Lean Management Subject Matter Experts


    Flevy's document contributors are Subject Matter Experts in their respective industries. Below, we have showcased our authors that specialize in Lean Management and Lean Six Sigma. Each of these authors and their respective consulting firms have developed training guides on Lean Six Sigma.

    Allan Ung, founder of Singapore-based Operational Excellence Consulting, has over 30+ years of experience playing global and regional roles leading Lean, Six Sigma, and TQM initiatives in global organizations such as IBM, Microsoft, Underwriters Laboratories, and Infineon Technologies.

    His firm provides corporate learning programs and management advisory services to assist clients to achieve breakthrough in business performance and effectiveness. Operational Excellence Consulting works with government bodies, multinational corporations, and small and medium-sized enterprises of a wide spectrum of industries. Some of their valued clients include Analog Devices, Borouge, Micron Technologies, B|Braun Medical Instruments, Panasonic, NEC, NileDutch, CLS Communication, Elsevier, Wow Education, Ministry of Social & Family Development, Temasek Polytechnic, Defence Science & Technology Agency, Immigration & Checkpoints Authority, etc.

    » View Allan's Lean Management training guides here

    Frank Adler, co-founder of US-based Operational Excellence Consulting, has over 25+ years of international executive leadership experience in General Management, multi-site Operations & Supply Chain Management, Quality & Customer Support Management, and Operational Excellence, Lean Management & Six Sigma.

    Frank is a certified and experienced Lean Six Sigma Master Black Belt, with a proven track record of implementing these methods, concepts and tools in various organizations and industries. He holds a in Mathematics and Physics from the Freie University of Berlin (Germany) and a in Applied Mathematics and Industrial Economics from the Helsinki University of Technology (Finland).

    His firm provides assessments, training solutions, kaizen event facilitation, and implementation support to organizations that are committed to achieve superior performance through Operational Excellence.

    » View Frank's Lean Management training guides here

    Vishnu Rayapeddi, founder of Productivity Solutions, is a management executive with over 30+ years of experience in End-to-end Supply Chain Management, Manufacturing Operations Management, Strategic Planning, Business/Operational Excellence, and Process Re-engineering/Improvement.

    Vishnu is a pioneer in Lean Management, combining the power of Lean Thinking, TOC, Six Sigma, TQM, TWI, Balanced Scorecard, cGMP, and other best-class methodologies like DMAIC, Value Stream Mapping, Root Cause Analysis, 5S, Quick Changeovers, Quality and Reliability, TPM, Visual Management, Standard Work, Pull, JIT, and Kanban.

    Vishnu has worked in Pharma Manufacturing and FMCG Supply Chain environments for over 21 years with some of the most reputed organisations in New Zealand and India, including Unichem Laboratories, Aristo Pharmaceuticals, Intas Pharmaceuticals, Standard Medical & Pharmaceuticals Ltd, Fonterra, George Weston Foods (part of AB Foods) and others. In the past 6 years, Vishnu has been providing consulting, training, coaching and mentoring services in the Operational Excellence arena.

    » View Vishnu's Lean Management training guides here

    Hemant Gham, founder of QMaxima, is an executive with over 20+ years of strategic and program-level experience leading Business Transformation, Performance Improvement, Lean Six Sigma, Change Management, and Customer Experience initiatives with over $40M+ contribution to the bottom line.

    Hemant is a Lean Six Sigma Master Black Belt with an extensive track record applying Lean Six Sigma principles, Change Management tools, Standardization and Agile/Product Management techniques. He has trained 300+ Green Belts/Black Belts who have become successful leaders.

    His firm QMaxima helps organizations focus and achieve productivity gains, stable operations, reductions in cost through improvements, standardize processes and improve workflows. QMaxima offers a wide range of services from Lean Six Sigma Deployment to Kaizen workshops to Custom Tool Development.

    » View Hemant's Lean Management training guides here




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    These best practices are of the same caliber produced by top tier consulting firms, like McKinsey, Bain, and Deloitte. Most documents were developed by seasoned executives and consultants with 20+ years of experience. The training guides selected below have all been developed by management consulting firms specializing in Lean Management and Lean Six Sigma. The select training guides below have all been developed by the subject matter experts showcased above.



    The office, by any name, is a paperwork factory. To become a Lean enterprise, office activities must fully support shop-floor manufacturing operations to eliminate waste. The [read more]

    Value Stream Mapping (VSM) is a lean management technique used to analyze the flow of materials and information currently required to bring a product or service to a [read more]

    The PDCA cycle, also known as the Deming Cycle or the Shewhart cycle, is a four-step continuous improvement process that is widely used in quality management, business [read more]

    [NOTE: Our Lean Manufacturing presentation has been trusted by an array of prestigious organizations, including industry leaders such as Apple, DHL, Cummins, [read more]

    The 8D Problem Solving Process has become a standard in many industries as problem solving or improvement process, as internal Corrective Action Request (CAR) Process or [read more]

    The Gemba Walk Slide Deck is a comprehensive and professionally designed resource that equips leaders and teams with the tools and knowledge to drive meaningful improvements [read more]

    Visual management is a powerful tool for conveying important information in a simple and easy-to-understand format. This practice involves displaying information in a visual [read more]

    [NOTE: Our Lean Office presentation has been trusted by an array of prestigious organizations, including industry leaders such as Apple, DHL, Cummins, Stryker, [read more]

    In manufacturing operations, standardization is a key element in eliminating process waste and excess inventory and in achieving balanced and synchronous production. Standard work [read more]

    This comprehensive slide deck is designed specifically for senior leaders, strategists, and cross-industry professionals who aim to drive transformative growth and operational [read more]

    The Lean Six Sigma - Process Risk Analysis & Mistake-Proofing Training Module provides you with a step-by-step approach, as well as examples, exercises, and templates, to analyze [read more]

    The TWI Job Instruction (JI) program trains supervisors in how to instruct a person to perform a job correctly and safely; and to be productive as quickly as possible, [read more]

    The Lean - Standard Work Training Module includes: 1. MS PowerPoint Presentation including 113 slides covering - History of Lean Manufacturing, - The Five Lean [read more]

    Please read the Preview Document "Lean Six Sigma 50 Tools Bundle Information Booklet" for complete details. The 50 Lean Six Sigma Tools file can download to your desktop [read more]

    This presentation has 114 slides and and comprises of the following: * What is Kaizen? * The 10 Commandments of Continuous Improvement * Value versus Waste concept * The 7 [read more]

    Lean 5S Visual Workplace Organization describes a systematic approach how to organize a workspace or area for efficiency and effectiveness by identifying and storing the items [read more]

    This Green Belt, Black Belt Training Design Aid Bundle includes: 21 PowerPoint Presentations 1630+ Slides 74 Minitab / Excel-based Exercises Use it as-is or to improvise [read more]

    This presentation has 46 slides and consists of: * What is culture and definitions * What is organisational culture? * How to develop OC * Leaders & Leadership * Great [read more]

    Lean-MBA stands for Lean Management Business Architecture. In essence it is the business architecture required to successfully manage Lean. The term "Lean" to me is a state of [read more]

    This is a 1 day presentation on Lean with over 100 slides, It also provides some self-assessment tools which can be used for group discussions. Define Vision & Mission What [read more]


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    Case Studies on Lean Management

    Lean Transformation Initiative for Automotive Supplier in Competitive Landscape

    Scenario: The organization in question is a tier-2 automotive supplier specializing in high-precision components, grappling with the escalation of waste and operational inefficiencies.

    Read Full Case Study

    Lean Enterprise Transformation for a High-Growth Tech Company

    Scenario: A rapidly growing technology firm in North America has observed a significant increase in operational inefficiencies as it scales.

    Read Full Case Study

    Lean Manufacturing Overhaul for D2C Fitness Equipment Provider

    Scenario: A firm specializing in direct-to-consumer fitness equipment is facing challenges in maintaining its operational efficiency.

    Read Full Case Study

    Global Lean Supply Chain Optimization in Aerospace

    Scenario: An established aerospace firm is grappling with the complexities of a globalized supply chain that has been impacted by fluctuating demand, increased competition, and geopolitical disruptions.

    Read Full Case Study

    Growth Strategy for Agritech Company in Precision Farming using Value Stream Mapping

    Scenario: An emerging agritech company specializing in precision farming faces operational inefficiencies and scalability issues, despite the growing demand for sustainable agriculture.

    Read Full Case Study

    Lean Enterprise Transformation for Power & Utilities Provider

    Scenario: The company is a regional power and utilities provider facing operational inefficiencies and escalating costs.

    Read Full Case Study

    Lean Management Improvement for a Global Retail Organization

    Scenario: A global retail organization, with a network of stores across five continents, has seen a substantial increase in operations' complexity as it tries to maintain its competitiveness.

    Read Full Case Study

    Lean Management Advancement for E-Commerce in High-Tech Sector

    Scenario: A high-tech e-commerce firm is grappling with operational inefficiencies and waste across its supply chain and customer service processes.

    Read Full Case Study

    Lean Transformation Project for a Large-scale Manufacturing Firm

    Scenario: A multinational manufacturing firm seeks to utilize Lean principles to optimize its manufacturing processes.

    Read Full Case Study

    Lean Manufacturing Strategy for Mid-Size Semiconductor Manufacturer

    Scenario: A mid-size semiconductor manufacturer, specializing in advanced chip solutions, faces 20% production inefficiency due to outdated processes and increasing competition.

    Read Full Case Study

    Lean Supply Chain Optimization Strategy for Trade Company in Asia

    Scenario: A prominent trade company in Asia, specializing in consumer goods, faces a strategic challenge in maintaining a lean supply chain.

    Read Full Case Study

    Lean Manufacturing Enhancement in Building Materials

    Scenario: The organization is a mid-sized producer of building materials in North America, grappling with the challenge of reducing waste and improving efficiency across its manufacturing facilities.

    Read Full Case Study


    FAQs on Lean Management

    How can Lean Thinking be adapted for remote or hybrid work environments to maintain efficiency and employee engagement?
    Adapting Lean Thinking for remote or hybrid work involves streamlining Communication, empowering Teams, fostering Continuous Improvement, and utilizing digital tools to maintain Efficiency and Employee Engagement. [Read full explanation]
    How can organizations overcome the challenge of maintaining momentum and employee engagement in Lean initiatives over the long term?
    Organizations can maintain momentum in Lean initiatives by ensuring Leadership Commitment, building a Continuous Improvement Culture, and employing effective Communication and Engagement strategies. [Read full explanation]
    How can Internet of Things (IoT) devices be leveraged within Lean Management frameworks to further reduce waste and improve process efficiency?
    IoT devices enhance Lean Management by enabling Real-Time Data Collection and Analysis, Predictive Maintenance, Quality Control, and Enhanced Decision-Making Processes, significantly reducing waste and improving efficiency. [Read full explanation]
    How can Lean principles be applied in the context of cybersecurity to improve organizational resilience?
    Applying Lean principles to cybersecurity enhances organizational resilience by streamlining processes, fostering collaboration, reducing silos, and implementing effective metrics for continuous improvement and efficiency. [Read full explanation]
    What are the best practices for integrating Value Stream Mapping with digital transformation efforts?
    Integrating Value Stream Mapping with Digital Transformation involves setting clear objectives, leveraging technology to optimize value streams, and focusing on Continuous Improvement for efficiency and customer satisfaction. [Read full explanation]
    What role does Lean Management play in enhancing data governance and quality management in the era of big data?
    Lean Management improves Data Governance and Quality Management in the big data era by streamlining processes, reducing waste, ensuring data integrity, and promoting continuous improvement and employee involvement. [Read full explanation]
    How can Lean methodologies be adapted to enhance innovation and creativity within organizations, beyond just operational efficiency?
    Adapting Lean methodologies to enhance innovation involves integrating Lean with innovation processes, fostering a culture of Continuous Improvement, and leveraging Lean for Strategic Innovation to unlock growth and competitiveness. [Read full explanation]
    What is TPS in operations management?
    TPS in operations management is the Toyota Production System, emphasizing waste elimination, continuous improvement, and employee involvement to drive Operational Excellence and quality. [Read full explanation]

    Explore all our resources on Lean Management



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