Lean manufacturing is more than a collection of strategies, it’s a way of thinking. The Lean system works to create value through the elimination of non-value-added activities and a philosophy of continuous improvement. Lean companies work to understand customer value, meet their expectations with quality products, and operate a process with zero waste. This mindset applies to all business activities – even suppliers and subcontractors - throughout the supply chain.

The principles at the core of Lean manufacturing were first introduced as part of the Toyota Production System in Japan. Toyota is known for developing the Lean tools Kanban, Gemba, 5S, and more, all focused on optimizing processes and eliminating waste. Lean manufacturing was coined in the 1990s as a manufacturing theory and today, Lean has been implemented in organizations worldwide where they are often combined with other improvement methodologies like Kaizen events and Six Sigma.

The five principles of Lean were adopted from the four principles identified by TPS. Like TPS, Lean is centered on waste elimination and continuous improvement but unlike TPS, Lean principles are more process-oriented. The key principles to Lean manufacturing are value, value stream, flow, pull, and perfection.

Creative Safety Supply is dedicated to providing industry professionals with comprehensive Lean manufacturing resources for all experience levels. We have gathered expert articles, blogs, podcast episodes all about Lean and even answered some of the most commonly asked questions. Explore the origins of Lean and its impact on organizations, discover the tools that improve efficiency and productivity, and get your company started on the Lean path.

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Lean Manufacturing Articles

Quality Control

Quality Control

Quality Control helps ensure products are meeting customer needs and reduce the risk of product defects. Let this article help get you started.

Kaizen and Lean Manufacturing

Kaizen and Lean Manufacturing

Going “Lean” is all about continuous improvement. Kaizen gives Lean manufacturers the tools and strategies they need to identify wastes in their facility and effectively eliminate them.

A Brief History of Kaizen: The Key Players

A Brief History of Kaizen: The Key Players

Kaizen has been shaped over the years by an automobile manufacturer, American statisticians, influential businessmen, and more. We explore who had a hand in creating Kaizen and how it has developed into the philosophy we know today.

An In-Depth History of the Kaizen PDCA Cycle

An In-Depth History of the Kaizen PDCA Cycle

Lean organizations focus on improving all parts of a process from start to finish in order to increase the quality of the results. Through the use of specific cycles (like PDCA), organizations can improve the processes and end products.

ISO 9001: 2015

ISO 9001: 2015

ISO 9001: 2015 is a standard that outlines and defines requirements for a quality management systems. This QMS certification allows companies to demonstrate to clients that they take quality and efficiency seriously.

Implementing Kanban

Implementing Kanban

Kanban’s inventory system has transformed the way the world manufactures. This article outlines how to implement Kanban successfully and efficiently.

DMAIC Cycle

DMAIC Cycle

The DMAIC cycle is the foundational method of Six Sigma, the Lean manufacturing method that radically reduces defects in production and infinitely improves efficiency. Learn how to implement Six Sigma into your facility with DMAIC.

Safety Committee

Safety Committee

Implementing a safety committee can help improve the overall safety of your company. Discussing safety concerns and resolving them will keep your employees safe.

Quality Control in Manufacturing

Quality Control in Manufacturing

Quality control in manufacturing is essential to maintaining a good customer base and keeping rework costs down.

5S Lean Training

5S Lean Training

If you’re new to the concept of 5S, you’ve probably feel confused. This article aims at providing clarity and setting you on the path toward understanding 5S and Lean.

Kanban Production System

Kanban Production System

Kanban Production Systems are an organizational system that produces big results by taking a series of small steps. Find out more...

Barcode Labeling

Barcode Labeling

Barcode labeling can help improve efficiency and overall accuracy when working with individual items. Learn how barcode labeling can help improve your business today.

Six Sigma Certification

Six Sigma Certification

Are you wanting to learn more about Six Sigma certification? Review this basic information on what it takes to become Six Sigma certified.

Critical Path Method (CPM)

Critical Path Method (CPM)

The critical path method (CPM) is a tool for planning and managing projects. The method can help you create and execute a project schedule, and it’s designed to maximize efficiency.

Mass Production

Mass Production

Mass production is simply the manufacturing of a large number of identical or very similar products. This type of production has been around for a long time, and it has its advantages and disadvantages.

House of Lean

House of Lean

The house of lean involves strategic planning and understanding to establish results of efficiency, safety, and process improvement.

What is QCDSM?

What is QCDSM?

QCDSM: Quality, Cost, Delivery, Safety and Morale. Learn how this simple lean principle can help your business.

8 Wastes of Lean

8 Wastes of Lean

The 8 Wastes of Lean is a much-needed update to the what the Toyota Production System called the 7 Wastes of Lean. Fighting these wastes head on will help your facility run more smoothly and efficiently.

Six Sigma Belt Levels

Six Sigma Belt Levels

Have you ever wondered what the Six Sigma belt levels are? Learn the requirements for each belt level and what it will do for your organization.

Supply Chain Integration

Supply Chain Integration

Supply chain integration refers to the process of integrating all parts of fulfillment into one single system. Learn the steps to get your supply chain integrated into an easy-to-manage system.

Organizational Development Process

Organizational Development Process

Organizational development process is an improvement methodology designed to take known problems and implement changes in order to overcome them.

What is a Thermal Printer?

What is a Thermal Printer?

Thermal printers are essential to printing in an industrial setting. Learn about the two types of thermal printing to determine which one suits your facility’s needs.

Tool Storage Ideas

Tool Storage Ideas

Lean manufacturing emphasizes organization, but it can be difficult figuring out just how to get started. This article lays out some common and effective ways of getting organized quickly.

Six Sigma Black Belt

Six Sigma Black Belt

For people wanting to master the six sigma methodologies, earning six sigma belts is the best way to master the principles associated with Six Sigma.

Six Sigma Green Belt

Six Sigma Green Belt

Earning a Six Sigma green belt is the first step toward mastering Six Sigma methodologies. Learn how to get started here.

Value Stream Mapping (VSM)

Value Stream Mapping (VSM)

Value stream mapping (VSM) gives a comprehensive look at a business’s production process. Once a business has their process mapped out, it’s easy to identify the places where waste happens.

What is Jishuken?

What is Jishuken?

Are you a leader looking to understand the benefits of Jishuken? We breakdown the definition of Jishuken and how it can improve efficiency in your workplace.

Lean Healthcare

Lean Healthcare

Implementing lean healthcare in the medical field will lead to improvement in overall performance and patient satisfaction.

What Is a Kaizen Event?

What Is a Kaizen Event?

Learn how to implement a kaizen event and improve your lean manufacturing strategy.

Floor Marking for Facility Safety

Floor Marking for Facility Safety

The best way to enhance safety is keeping workers informed, and floor markings are the most reliable, durable method of ensuring that everyone is aware of potential hazards.

Perpetual Inventory System

Perpetual Inventory System

Using a perpetual inventory system is a great way to keep track of inventory, ordering, and other related tasks in order to keep your business running efficiently.

Industrial Floor Marking Guidelines

Industrial Floor Marking Guidelines

OSHA doesn’t offer much guidance on how floor markings should be installed, so we’ve compiled some helpful tips and best practices to ensure your markings are useful, straightforward, and helpful to everyone in your facility.

Floor Marking For 5S

Floor Marking For 5S

Inexpensive yet endlessly practical floor markings can drastically simplify your 5S efforts, while saving you time and money. Learn more in our latest article.

Asset Tags

Asset Tags

A simple yet powerful organization tool, asset tags reduce theft, enhance inventory management efforts, and make it easier for employees to find exactly what they need exactly when they need it.

Theory of Constraints

Theory of Constraints

Whether you know it or not, something is holding your business back, and the Theory of Constraints can help you find it.

Floor Marking for Fire Extinguishers

Floor Marking for Fire Extinguishers

Use floor markings to make sure you can find the fire extinguisher and that it is not blocked in an emergency.

Overall Equipment Effectiveness (OEE)

Overall Equipment Effectiveness (OEE)

Are your lean and 5S efforts making a difference? Crunch the numbers on OEE to find out!

Total Productive Maintenance (TPM)

Total Productive Maintenance (TPM)

Learn how you can reduce downtime, improve efficiency, and enhance employee morale all in one fell swoop with Total Productive Maintenance.

8D for Problem Solving

8D for Problem Solving

The 8 Disciplines (often seen as the acronym “8D") is a problem-solving method initially developed by the Ford Motor Company to resolve a wide variety of problems in any professional environment. Find out how the 8D method can benefit your workplace.

Lean Logistics

Lean Logistics

Lean logistics is a detailed implementation or organization of an operation that is more complex in nature than what you see in standard lean strategy.

Kano Model

Kano Model

Using the Kano model is beneficial when evaluating what your consumers like, need or expect from your product or services. Learn more...

5S System

5S System

A 5S system is an effective way to manage workplace organization in almost any environment. Check out how it can lead to success in your workplace.

Statistical Process Control (SPC) in Manufacturing

Statistical Process Control (SPC) in Manufacturing

Statistical Process Control also known as SPC, is a term used in quality control. Find out how you can use this continuous improvement method.

Bottleneck Analysis

Bottleneck Analysis

Learn to avoid hang ups that lead to bottlenecks with these helpful tools and tactics to improve quality and efficiency.

Quality Circle

Quality Circle

Quality circle is a group of employees within the same job role that collaborate together to discuss ways to fix or improve processes. Learn more ›

Creating a Visual Workplace

Creating a Visual Workplace

Creating a visual workplace can help improve efficiency and reduce workplace injuries. Check out these tips for creating a visual workplace.

Warehouse Management

Warehouse Management

Proper warehouse management can dramatically improve both efficiency and safety. This article covers everything you need to know.

Six Sigma Principles

Six Sigma Principles

Find out how to properly implement six sigma principles to promote success in your business.

Learning and Implementing the Lean Process

Learning and Implementing the Lean Process

Learning the basics about the lean process is essential when implementing continuous improvement changes. We have broken down the lean process so its easy to understand.

Fault Tree Analysis

Fault Tree Analysis

Understanding fault tree analysis can help you find the root cause to an issue to help it become resolved. Learn about implementing fault tree analysis in your industry.

Understanding the Toyota Production System

Understanding the Toyota Production System

The Toyota Production System, or TPS, brings improved organization to a facility, reduces waste, and can improve the bottom line of companies that adopt it.

Introduction to Process Mapping

Introduction to Process Mapping

Process Mapping is used in many types of businesses to help companies streamline their production, increase profitability, reduce waste, and much more.

Understanding Cross Docking

Understanding Cross Docking

Cross docking is a logistical strategy where products and materials are unloaded from one inbound sourceand then immediately moved onto outbound transportation with as little storage time as possible.

How Can a Balanced Scorecard Help Your Facility?

How Can a Balanced Scorecard Help Your Facility?

A balanced scorecard is an effective management system that helps organizations better accomplish their goals and can be used effectively any type of business.

Focusing on Continuous Improvement in the Workplace

Focusing on Continuous Improvement in the Workplace

Facilities that focus on continuous improvement become more competitive over time and can maintain their advantages in their industry, but only if the improvement efforts are done correctly.

Process Cycle Efficiency

Process Cycle Efficiency

Process Cycle Efficiency is a metric commonly used by those following Lean and/or Six Sigma principals. It is calculated by taking value-added time and dividing it by lead time. The answer is a percentage, and the goal is to be as close to 100% as possible.

Value-Added vs. Non-Value-Added Activities

Value-Added vs. Non-Value-Added Activities

The terms value-added and non-value-added are often used when evaluating changes in products, workflow production and process improvement. Categorizing activities will help identify what activities should be maintained and which ones should be adjusted or eliminated.

Batch Production

Batch Production

Batch production involves the facility completing specific tasks all together, in batches, rather than completing a full process on its own, to help improve efficiency and reduce wasted time.

FOCUS-PDCA

FOCUS-PDCA

FOCUS-PDCA is a business strategy designed to help improve processes. It is an acronym for the steps and actions that need to take place during the process improvement period.

How to Implement 5S in an Organization

How to Implement 5S in an Organization

It takes significant effort to implement a proper 5S program, but following the right steps will drive success and help the process go smoothly.

5 Lean Manufacturing Tools that Work

5 Lean Manufacturing Tools that Work

These five lean manufacturing tools are essential for making your lean journey a success.

Getting Started with Kaizen

Getting Started with Kaizen

Proper training is key for getting started with Kaizen and on the road to continuous improvement.

Floor Marking Ideas for Warehouses

Floor Marking Ideas for Warehouses

Warehouse floors provide an opportunity for visual communication. Find out what floor signs, tapes, and shapes you can use.

Genchi Genbutsu

Genchi Genbutsu

Genchi genbutsu, a Japanese term meaning “go and see,” can change how managers and company leaders interact with the workplace.

Chaku Chaku

Chaku Chaku

This Lean concept can improve the way manufacturing cells function by organizing space in specific ways.

Understanding Hoshin Kanri

Understanding Hoshin Kanri

This Lean term for “policy deployment” can help keep everyone in an organization on the same page.

Lean Supplies

Lean Supplies

Learn what supplies and tools you can use to make Lean manufacturing efforts successful.

Six Sigma

Six Sigma

Learn the essential elements of Six Sigma and the levels of certification.

Gemba

Gemba

This Japanese word for "the real place" can change the way managers approach employees and their work.

Kanban

Kanban

A kanban system uses visual cues to trigger actions. Find out how it can regulate production.

Lean Manufacturing

Lean Manufacturing

This business model seeks to eliminate waste and increase value in work processes.

5S Study and Research

5S Study and Research

One of the most comprehensive pages you will find on 5S.

19 Tool Foam Hacks and Tips for Your Tool Drawers

19 Tool Foam Hacks and Tips for Your Tool Drawers

Use these tool foam organizer tips and hacks get your workspace in order and simplify your life.

What is Kaizen?

What is Kaizen?

The concept of Kaizen will help any organization through continuous improvement.


Lean Manufacturing Questions and Answers

Is mass production considered Lean?

Mass production, traditionally, has not been a Lean strategy for manufacturing. Instead, Lean manufacturing heavily relies on a pull system (just-in-time) rather than a push system (mass production). The difference… 

How do I Process Map?

Process mapping is seen as the essential first step to any process improvement effort and is a powerful tool in for any Lean organization. It will give managers a better… 

What are the 5 Whys?

When problems pop up in the workplace, it can be tempting to fix it quickly. However, not finding and addressing the root cause of the issue can lead to recurring… 

What is Heijunka?

A critical element to the Toyota Production System and Lean manufacturing is Heijunka, a Japanese concept translating to mean “production leveling.” The goal of Heijunka is to smooth out production… 

What are fishbone diagrams?

Fishbone diagrams are a Lean problem-solving tool used to identify the root cause of an issue. The goal is to reveal relationships between variables Performing a root cause analysis is… 

What is value stream mapping?

Value steam mapping is a Lean method used for reducing waste, planning improvement activities, evaluating progress, and more. The Toyota Motor Company is credited with developing and implementing the original… 

How is OEE calculated?

Overall equipment effectiveness (OEE) is a Lean metric considered to be the gold standard for evaluating manufacturing operations. OEE is a percentage representing the amount of manufacturing time is truly… 

What is just-in-time (JIT) manufacturing?

Just-in-time (JIT) manufacturing is a term used synonymously with the Toyota Production System (TPS), the methodology that Lean manufacturing is largely based upon. The exact details of JIT’s origins are… 

How do I create a balanced scorecard?

Balanced scorecards are a Lean tool used to connect day-to-day operations with the big picture goals of an organization. It is a system that helps prioritize projects and products while… 

How do I create a value stream map?

Value stream maps represent the flow of materials, work, ad information through the facility and are a Lean tool used to identify areas of improvement. While creating a value stream… 

What is Muda?

Muda is a Japanese term meaning futility, wastefulness, or uselessness. In the context of Lean manufacturing, muda is a key concept as one of three types of waste (muda, mura,… 

What is 8D?

The Eight Disciplines (8D) of problem solving is a model used to effectively identify and solve recurring problems. While most Lean tools are derived from the Toyota Production System, 8D… 

How do I calculate Takt time?

Takt time represents the average amount of time needed to adequately meet customer demand while not operating  over capacity. Takt time is calculated with the following equation: Takt time = Ta… 

What is a value stream?

A value stream represents all of the activities, from start to finish, that take place in the production process. Value stream mapping, mapping the flow of goods from the supplier… 

What is a balanced scorecard?

Balanced scorecards are a management system often used in Lean workplaces. This strategy works to drive performance while keeping everyone in the organization accountable. Balanced scorecards are a great tool… 

What is poke yoke?

Poka yoke is something you might hear when talking about Lean manufacturing. It is a Japanese term meaning “mistake proofing,” and was developed as part of the Toyota Production System.… 

What is the SCAMPER method?

SCAMPER is a tool used to ignite and foster creativity in collaboration. It is used in classrooms by students, in conference rooms, offices, and so many more places. First proposed… 

What is a perpetual inventory system?

A perpetual inventory system, sometimes called a continuous inventory system, is a method for managing inventory with real-time updates about what a facility has on hand. The system is updated… 

When was Lean manufacturing invented?

Although Lean principles can be traced back to the 18th century, in order to understand the Lean business model used today you have to look at the relationship between American… 

What is the goal of Lean?

Lean thinking is used by companies who are looking to improve efficiency and eliminate wastes. The ultimate goal for Lean manufacturing is to create quality products that satisfy the customer… 

What is takt time?

Takt time is a commonly used metric in Lean manufacturing for effectively managing a pull system. The concept was first used as a project management tool by the German aircraft… 

What is process mapping?

Process mapping is a tool used to show the sequence of steps within a business process from beginning to end. Mangers and Lean practitioners use process mapping to evaluate workflow,… 

What is cross docking?

Cross docking is a logistical strategy used in supply chain management that looks to improve efficiency through warehousing and distribution efforts. In traditional manufacturing companies, products are stored in a… 

What is lead time?

In the most basic sense, lead time is the amount of time elapsed between a customer placing an order to when that order is sent out for delivery. In manufacturing,… 

What are bottlenecks and how can I fix them?

Simply put, bottlenecks are areas in the manufacturing process where work is held up. It’s a stage within the process where requests outnumber the throughput constraint, causing an interruption to… 

How does someone become certified in Lean manufacturing (Six Sigma)?

While a company does not have to have anyone certified in Lean manufacturing (Six Sigma) to implement Lean manufacturing strategies, it will certainly help. Those who become certified will learn… 

Which automobile company initialized Lean manufacturing?

The basic concepts of Lean manufacturing have a very long history, going back many hundreds of years. These concepts include waste reduction, improved efficiency, and more. Lean as we see… 

Are people or processes more important in Lean manufacturing?

When implementing Lean manufacturing in a facility most managers will notice that there is endless information about the processes used to make it a success. There is no doubt that… 

What is the Lean methodology?

Lean methodology, whether used in manufacturing, health care, or any other industry, is a concept where a business attempts to create a flow of value to the customer through specific… 

Who should be involved in Lean manufacturing?

Any facility that is looking to implement or expand Lean manufacturing will have to take a close look at who should be involved in the process. The fact is, Lean… 

How does Lean manufacturing eliminate waste?

The main reason companies look to implement Lean manufacturing strategies is to help them eliminate waste. Cutting out waste will reduce their expenses and maximize profits so that they can… 

What is needed in a Lean 5S toolkit?

In Lean workplaces there will typically be one person, or a small group of people, who are responsible for ensuring the standards for Lean are followed. They will, of course,… 

Is Kaizen an alternative for Lean Six Sigma?

Facilities that are looking into ways to make improvements they will undoubtedly run into a lot of different options, which can lead to confusion. Two of the most common terms… 

Where do I start with Lean manufacturing?

Any company that is looking into implementing Lean manufacturing standards is going to run into one significant obstacle. Where to start. While there is endless documentation and recommendations on ways… 

What are Lean manufacturing tools?

Lean manufacturing facilities use a variety of tools and strategies to maximize efficiency and eliminate waste. Unlike strict process improvement methodologies, Lean is more of a high-level strategy or concept… 

What are principles of Lean manufacturing?

Any company that is thinking about implementing Lean manufacturing strategies will want to take some time to learn about the main principles behind this methodology. While most people simply associate… 

What is Lean manufacturing?

Lean manufacturing is a system used in the manufacturing industry to help identify and eliminate waste. In practice, Lean manufacturing breaks the broad concept of waste into several sub-categories to… 

What is the Lean manufacturing process?

The specific processes used by a company that is following Lean Manufacturing techniques will vary based on their business model. All Lean Manufacturing companies, however, will need to follow the… 

What are the 7 (or 8) wastes of Lean manufacturing?

Lean manufacturing is focused on waste identification and elimination in the workplace. When using this program, it is necessary to get specific in regard to what types of waste exist,… 

How can Lean manufacturing help a company?

If you are thinking about implementing Lean manufacturing in your facility, you will want to take some time to understand how it will help the company. Most people understand that… 

How can I implement Lean manufacturing?

Implementing Lean manufacturing into your facility can help to identify and eliminate many types of wastes, which can have big benefits for your bottom line. Getting started off on the… 

How is Lean different from Six Sigma?

When looking for ways to improve a business, many people will look at Lean manufacturing and Six Sigma and see a lot of similarities. While it is true that they… 

What is Lean management?

In order to successfully implement Lean manufacturing, you need to have the leadership exercising Lean management strategies. This is when leaders push the concept of continuous improvement and waste elimination… 

Why is Lean manufacturing called Lean?

Lean manufacturing is a very popular strategy that helps companies to reduce waste so they can improve the bottom line of their facility. The strategy is so popular that many… 

What are Lean terms?

When working to start or expand a lean manufacturing system, you will run across a variety of different terms. If you’re not familiar with them, it can be quite confusing.… 

Lean Manufacturing Blog Posts

Lean Manufacturing Infographics

5S is the Foundation of any Lean Program

5S is the Foundation of any Lean Program

Text From Infographic 5S is the Foundation of any Lean Program WHAT IS 5S? The 5S methodology is a systematic approach to workplace… 

Stop Buying Labels from a Catalog

Stop Buying Labels from a Catalog

Six reasons you should stop buying labels from a catalog and start printing your own labels with an industrial label… 

Tool Organization with Foam Kits

Tool Organization with Foam Kits

Tool Organization and Control with Foam Kits EMPTY your tool drawer. MEASURE the inside dimensions of the drawer. MARK AND… 

Gemba: A Powerful Piece of your Lean Toolbox

Gemba: A Powerful Piece of your Lean Toolbox

Gemba – A Powerful Piece of Your Lean Toolbox Gemba is a straightforward way for business owners and managers to find… 

The Importance of Industrial Label Printers

The Importance of Industrial Label Printers

The Importance of Industrial Label Printers in the Workplace Safety 2.8 million workplace injuries occur every year in the US alone.This equates… 

Poka Yoke: What's it all about?

Poka Yoke: What's it all about?

Poka Yoke: What's it all about? Poka Yoke is a simple concept that is often used in manufacturing. It means “mistake-proofing.”… 

Lean Manufacturing Podcasts

Continuous improvement can make a process better, improve safety and save dollars. But it's a waste of time if the… 

Respect For People is a crucial part of lean and A3. Lean guru Bill Greider tells how A3 teams can… 

Lean IT expert Steve Bell helps solve the long-standing battle between a company’s goal of Continuous Improvement and the perceived… 

Continuous improvement is best started with management on board. Expert in the field, Jeff Hajek, describes the structure a company… 

Lean success means increasing safety and efficiency. Yes, improve operations and save money simultaneously. Lean implementer Matt Wrye explains how. Matt… 

The old suggestion box used to be a fair way for employees to offer ideas at their organization. However, over… 

Kaizen events that rock—time to increase efficiency in your organization! Lean/Six Sigma expert Mark Hamel tells of how to implement… 

Why do workers resist lean culture? Lean methodology expert Karen Wilhelm explains why employees are often suspicious of lean, and… 

Starting Lean Six Sigma, Pt. 2 continues with Six Sigma Black Belt Chuck Hardy. Chuck tells of the value of… 

Starting Lean Six Sigma with an expert. Chuck Hardy is a Black Belt in Six Sigma. Chuck tells of lean… 

Lean Methodology In Healthcare — hear Mark Graban on 5S, Six Sigma, and “lean Sigma” in the medical world. Mark Graban… 

Owners and managers—the bosses—don’t often like change. Try “continuous improvement” to improve safety and efficiency. Start with no budget, in… 

Lean safety is the result of implementing “lean” methodology. Lean makes businesses less wasteful, more efficient and more profitable. An… 

Hazard labels give critical information. Labels are the glue that hold the whole safety system together. From manufacturing to office settings,… 

Industrial labels are cheaper to make in-house. And quicker. For a manufacturing, in a warehouse, or almost any work site,… 

Increase efficiency by red-tagging items you don’t need immediately. Store them or get rid of them. Red tagging is part of… 

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