What is it?

Lean production is a production methodology focused on eliminating waste, where waste is defined as anything that does not add value for the customer. Although Lean's heritage is manufacturing, it is applicable to all types of organisation and all an organisation's processes. While the origins of Lean principles are not clear, Toyota has been instrumental in the development and application of Lean, and many tools are derived from the Toyota Production System (TPS). The tools are rooted in "The Toyota Way," which is focused on improving the flow or smoothness of production by eliminating unevenness in the production process. Lean methodology is not concerned with workarounds but with getting to grips with the root causes of waste. Lean defines seven types of waste, called the "Seven Deadly Wastes." These are:

What benefits does the process provide?

• Improved on-time delivery.
• Improved quality.
• Improved customer service and satisfaction.
• Simpler production process and, therefore, simpler production management.
• Reduced defects.
• Reduced resource consumption.
• Increased efficiency.

Implementing lean production? Questions to consider

• Is the current production system fully documented?
• Has the proposed production system been documented?
• Have senior leaders accepted the business case for change?
• Is the business case based on the wastes identified in the current process?
• Does the business case ascertain the Lean tools appropriate for the identified wastes?
• Have senior leaders and key implementation personnel been trained in applicable Lean techniques?
• Has implementation been fully planned and resources approved?
• Have the measures of success and targets been agreed?
• Are incentives in place to encourage buy-in to kaizen?