Lean manufacturing is more than a collection strategies, it’s a way of thinking. By implementing systems like Kaizen, 5S, Gemba, and more, you can create a more efficient and productive workplace. All of our Lean resources have been gathered here to get you started on the Lean path.
Lean Manufacturing Articles
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. …
Lean Manufacturing, Lean, Kaizen, Regulations & Compliance, Facility Efficiency, Continuous Improvement
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. …
Lean Manufacturing, Kaizen, Facility Efficiency, Six Sigma
¿Qué es 5S? ¿Cuál es la mejor manera de implementar 5S? Obtenga respuestas a sus preguntas 5S con nuestra página completa de capacitación y recursos de 5S. ¡Aprende más ahora! …
5S, Lean Manufacturing, Lean, Spanish Resources
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. …
5S, Lean Manufacturing, Kaizen, Kanban, Facility Efficiency, Gemba, Six Sigma
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. …
5S, Lean Manufacturing, Kaizen, Kanban, Floor Marking, Safety Signs, Facility Efficiency, Gemba, Six Sigma
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. …
5S, Lean Manufacturing, Kaizen, Kanban, GHS, Arc Flash, Pipe Marking, Electrical Safety, Safety Signs, OSHA, NFPA, Wire Marking, Labeling, Workplace Safety, Facility Efficiency, Mining Safety, Gemba, Hazcom, Fire Safety, Military Equipment, Safety, Six Sigma
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. …
Lean Manufacturing, Floor Marking, Forklift Safety, Safety
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 Manufacturing, Tool Organization, Facility Efficiency
Statistical Process Control also known as SPC, is a term used in quality control. Find out how you can use this continuous improvement method. …
5S, Lean Manufacturing, Kaizen, Kanban, Facility Efficiency, Continuous Improvement
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. …
5S, Lean Manufacturing, Kaizen, Kanban, Facility Efficiency, Gemba, Six Sigma, Continuous Improvement
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. …
5S, Lean Manufacturing, Kaizen, Kanban, Facility Efficiency, Six Sigma, Continuous Improvement
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. …
Lean Manufacturing, Facility Efficiency
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. …
Lean Manufacturing, Facility Efficiency
Lean Manufacturing Infographics
Text From Infographic 5S is the Foundation of any Lean Program WHAT IS 5S? The 5S methodology is a systematic approach to workplace organization, aimed at improving the efficiency and effectiveness of the …
5S, Lean Manufacturing, Workplace Safety, Facility Efficiency, Safety
Six reasons you should stop buying labels from a catalog and start printing your own labels with an industrial label printer Filling out lengthy order forms is a real drag...and …
Lean Manufacturing, Floor Marking, Safety Signs, Labeling, Workplace Safety, Hazcom, Safety
Gemba – A Powerful Piece of Your Lean Toolbox Gemba is a straightforward way for business owners and managers to find and remedy issues that can affect their production. Gemba walks can …
Lean Manufacturing, Workplace Safety, Facility Efficiency, Gemba, Safety
The Importance of Industrial Label Printers in the Workplace Safety 2.8 million workplace injuries occur every year in the US alone.This equates to 1 injury every 11 seconds. With proper training and …
Lean Manufacturing, Pipe Marking, Electrical Safety, Safety Signs, OSHA, Labeling, Workplace Safety, Facility Efficiency, Hazcom, Safety, Ammonia Pipe Marking
Lean Manufacturing Questions and Answers
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 map can be simply drawn on a piece of paper, there are a few best practices and elements you should be aware of before you… read answer
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, and muri) identified by the Toyota Production System. Muda refers to the seven wastes commonly found in Lean manufacturing as identified by Taiichi Ohno: Transportation:… read answer
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 was actually developed by the Ford Motor Company. 8D is made up of eight steps for problem solving, but many choose to include an additional step… read answer
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 ÷ D In this formula you need the total production time (Ta) and the rate of customer demand (D) in order to find Takt time. Total… read answer
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 all the way to the customer and detailing all the steps involved in the work process is a popular tool in Lean manufacturing. Breaking down… read answer
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 for monitoring day-to-day work and evaluating progress in the context of “the big picture.” High-level aspects of a company, or the big picture, are included in… read answer
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. Shigeo Shingo, an engineer at Toyota, is credited with the conceptualization of poka yoke, a technique for building and engineering mechanisms into a process that… read answer
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 by Alex Faickney Osborn in 1953 and later developed by Bob Eberele in 1971, SCAMPER was created as a way to enhance students’ knowledge and… read answer
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 right when materials come in or when an order goes out, consistently reflecting accurate inventory information. Perpetual inventory systems are the opposite of periodic systems,… read answer
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 and Japanese manufacturers. American business magnate Henry Ford revolutionized the manufacturing production process by developing what he called flow production. Automobiles being manufactured at this time… read answer
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 and meet demand with as little resources as necessary. Lean manufacturing came to popularity in the 1990s and derived most of its principles and philosophies… read answer
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 industry, eventually becoming popularized by Toyota and the Toyota Production System. Takt time is the maximum amount of time needed to completely manufacture a product… read answer
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, look for areas of improvement, and identify non-value-added activities. Whether you work in a restaurant or a manufacturing facility, a process map can be a… read answer
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 warehouse or other location often for long periods of time waiting for delivery. In Lean manufacturing however, that storage time and space is considered wasteful… read answer
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, lead time is made up of three different stages: Preprocessing Lead Time: Preprocessing or planning lead time, is the time after an order has been… read answer
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 the workflow and delays across the entire production process. For instance, a company manufacturing cars sends four cars every hour to the painting station. However,… read answer
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 the processes so that they can be implemented successfully. In addition, the certification process requires the individual to gain real, hands on experience with Lean… read answer
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 it today, however, really got its start in the early 1900’s. While many people credit the Toyota Motor Company for most of the major manufacturing… read answer
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 following these processes is essential for Lean manufacturing, which can lead some people to believe that it is the processes that are most important, not… read answer
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 concepts. Most people associate Lean with waste elimination, and that is a big result, but the real goal behind Lean is providing your customers with… read answer
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 manufacturing will require everyone in the facility to contribute in some way. While there may be a few people who act as the Lean leadership… read answer
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 be more competitive, and therefore more successful. Understanding how this methodology can eliminate waste will help to determine the benefits that a given workplace will… read answer
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, have help in making changes, finding root causes, and measuring success, but keeping the Lean 5S strategies moving forward will rest on their shoulders. This means… read answer
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 used in this field are Lean Six Sigma and Kaizen. At first glance, many people think of Kaizen as an alternative to Lean, or even… read answer
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 to perform Lean manufacturing techniques, there really isn’t very much out there that can help take these methodologies from an idea into production. Fortunately, it is… read answer
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 that will take advantage of what other systems have to offer. Part of Lean manufacturing is being able to determine which tools are the right… read answer
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 Lean manufacturing with waste reduction, there are a number of underlying principles that make it possible to successfully eliminate waste from the workplace. The following… read answer
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 make it easier to find and remove. Many companies have been able to save a significant amount of time, money, and other resources by using… read answer
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 same basic concepts or processes. This will allow them to identify the waste, find ways to eliminate it, and then implement those improvements. The steps… read answer
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, so that it can be more easily eliminated. With this in mind, the Lean manufacturing system classifies seven specific types of waste, and one additional… read answer
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 Lean manufacturing is a waste reduction and elimination program, but what does that mean on a practical level. Read on to get some good examples… read answer
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 right foot is important for ensuring you get the best results possible. The following are some key tips for implementing a Lean manufacturing program in… read answer
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 are both primarily focused on eliminating waste in the workplace. While their goals are similar, the methods that are used for achieving them is quite… read answer
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 from the top down. It is not sufficient just to have one Lean manager driving the concepts of Lean manufacturing throughout the facility. Instead, every leader… read answer
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 people never even think about the name anymore, but it is somewhat unusual. So, the question may arise about why it is called Lean Manufacturing.… read answer
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. While no facility uses every one of the terms listed, it is good to at least have a basic understanding of what they mean so… read answer
Lean Manufacturing Blog Posts
- How to Spring Clean Your Facility
- How to Start Lean and "What's Wrong With the Lean Start-up Process"
- Kaizen for the Workplace and Personal Spaces
- Safety and Lean Resources
- Can Your Office Benefit from Lean Strategies?
- Classic Vs. Modern Definition of Root Cause | Which is Better?
- Heijunka Box
- Genchi Genbutsu
- 5 Tips to Improve the Elimination of Waste
- Lean Manufacturing: Commonly Asked Questions
- How to Establish the Lean Supply Chain
- Kanban System Basics for Manufacturing
- Gemba Walk for Manufacturing
- Understanding Key Lean Manufacturing Concepts
- Seven Simple & Effective Manufacturing Safety Tips
- Kanban Process - Understanding the Steps for Better Efficiency
- 5S - For Life & For Business
- Lead Time Reduction In Five Easy Steps
- Lean is Green
- Eliminating Waste using these 5 Steps
- Increasing Warehouse Productivity
- Visual Control Boards
- 5S Red Tags – The Correct Way to Use A Simple Lean Tool
- Internet Usage – Does it Hurt Employee Productivity?
- 3 Ways To Use a Staging Area In Your Business
- Five Steps to Starting LEAN Successfully
- Panda Express - The Relationship Between Speed and Quality In Business
- Three Ways To Cut Non-Value Adding Processes From Your Business
- Andon Lights 101 – How to Use Andon to Improve Production Communication
- Why A Scorecard Is Not A Dashboard
- 8 LEAN Tools You Should Already Be Using
- 5s Supplies Improve Safety and Organization in Auto Repair Shops
- Business Performance Measurement Methods & Their Effectiveness
- How Safety & Lean Go Hand In Hand
- Kaizen Event Reduces Transport Waste & Optimizes Efficiency
- 6 Ways Lean IT Can Help Enterprises
- Helpful Tools to Make Layouts for a Production Line
- Lean Manufacturing in a Nutshell
- Chaku Chaku & Other Lean Terms You Should Know
- Yokoten: From In Theory to Implanted
- Temporary Consequences of Making the Change to Lean Manufacturing
- On the Constraints of Bottlenecks
- Heijunka – Increasing Efficiency
- Changeover: Streamlining Your Business
- Examples of the 5 Whys
- The JIT System
- Re-Inventing the Wheel – Do It Just This Once
- Shojinka: The Secret Ingredient of Highly Effective Production
- Improving Workplace Efficiency: One Lean Step at a Time
- Lean Takes Time
- Employee Involvement: It can Make or Break LEAN
- Lean Eliminates Waste, Not People
- What is Poka Yoke?
- Packaging Waste: Large Box Use Out of Hand?
- Overproduction is Overrated
- Talking Kaizen and Lean with Mark Hamel
- Workplace Safety: The Power of Praise
- TIMWOOD at Work!
- Going Lean: Five Common Misunderstandings
- NASA Embraces Technology through Continuous Improvement
- Can Data Collection Streamline Operations?
- Made in the USA – Reshoring with the Help of Lean
- Continuous Improvement: Mail Delivery of the Future?
- Want Results? 10 Continuous Improvement Strategies that Work!
- Improvement Comes from People Who Feel Secure
- Understanding True Alignment
- The Benefits of Lean Management
- How Does Flow Minimize Waste in Production
- Small Changes Add Up!
- 5S Factory
- Lean: Is Forecasting Feasible?
- Improvement: Make a Win-Win Situation for Both the Business and it's Employees
- Decision-Making: Is Quicker Always Better?
- The Importance and Value of Mistake Proofing
- Lean Metrics + Process Improvement = Success
- New Product Development: Potential Pitfalls
- Quality Begins with the Design and Process
- Value Stream Mapping
- Going Lean: IKEA style
- Motorola’s Six Sigma Program
- CpK Defined
- Internal Quality Auditing
- Using Quality Objectives to Drive Strategic Performance Improvement
- Performance Measurement in Health Care
- Verification vs. Validation
- Using Excel for Data Analysis
- Non-Normal Distributions in the Real World
- Disney Institute - Service Quality, Disney Style
- Self-Directed Work Teams
- Measuring and Managing Customer Satisfaction
- Definition of Quality
- Lean Posters
- Red Tags
- The Concept of Muri, Muda and Mura
- Important Information Regarding Foam Inserts
- A Lean Journey: Annual Management Improvement Carnival 2012
- Organization Transformation through Lean Manufacturing
- Keurig Coffee Makers Make Things Faster, Easier, But More Waste
- Lean Supply Chain
- Where is the Lean Manufacturing Case Study?
- How to introduce 5S concept in the work environment?
- Lean Supplies Chain Management for Companies
- With Election Over, Will Manufacturing Rebound?
- Lean Manufacturing Can Enforce Safety Standards
- What is the Future of U.S. Manufacturing?
- Who Is Interested in Lean Manufacturing?
- Lean Manufacturing Across the U.S.: From Salt Lake to Toledo
- Trashing the Top 5 Myths About Lean Manufacturing
- What is Lean Manufacturing? Watch this Cartoon
- Trying to Implement Lean Manufacturing? Educate Yourself First.
- Lean Book Reviews: How to Implement Lean Manufacturing
- Lean Manufacturing Just In Time : The Ultimate Inventory System
- A3 for Lean Implementation
- Henry Ford and Steve Jobs : A Comparison Between Two Titans of Industry
- Lean Manufacturing Ideas : Know What Is Worth Your Time
- Six Sigma Manufacturing : Waste Reduction and Process Enhancements
- Risk Management Webinar from EtQ on October 10, 2012
- Comparing the First 2012 Presidential Debate with Lean Leadership
- Lean Manufacturing Training : Key to Many Opportunities
- Project Management Best Practices Are Not Set In Stone
- Caine's Arcade : An Example of Lean?
- Lean Manufacturing : Value Stream Mapping Overview
- What's Your Problem? Now, Go Solve It!
- An Overview on Kanban Systems
- Which Way to Turn on the Lean Road?
- One Piece Flow Manufacturing and Production Video
- Manufacturing Reports: China is Taking U.S. Jobs
- Training to Use 8D Problem-Solving Tactics
- Practicing Lean Manufacturing to Optimize Resource Utilization
- Lean Manufacturing for the Monkeys?
- Is Lean Too Elitist?
- What's In It For YOU To Go Lean?
- See Manufacturing in action across the U.S. October 5, 2012.
- Respect for People and Continuous Improvement = Lean
- 3 Tips to Help Develop a Strong Lean Culture in Your Workplace
- Foam Tool Organizer and Its Accountability in the Work Place
- Get Lean with Pizza?
- 3P Lean : Exploring the Production Preparation Process
- Active Lean Implementation at GE Manufacturing Plant
- Change Your Ways To Success
- Always Good News : U.S. Industrial Output Rises .6% in July
- Ford Trying to Put More Americans Back to Work
- Leaders Lead! 3 Tips to Improve Your Leadership Abilities
- SAIC Poised to Lay Off Nearly 200 Employees in Florida
- In Leaner Times, Indian Apparel Companies Resort To Lean Manufacturing
- Sure, China's Manufacturing Grasp May Be Slipping, But What About the United States?
- Selling Old-Timers on Lean in Not-So-Lean Times
- American Manufacturing: Even the Olympic Team USA Uniforms Were Outsourced
- 10 Tips You Should Remember when Solving Problems
- Can An Autonomous Environment Truly Exist Successfully?
- Someone Started Everything for You?
- Lean Doesn't Work for Everything : Process Layout vs Cellular Layouts
- Does the kanban system promote efficiency or errors?
- Kaizen Events, How vital is it to Lean manufacturing
- Lean Misconceptions
- When Strict Rules Don’t Work in Lean Manufacturing
Lean Manufacturing Guides
Lean Manufacturing Products
Lean Manufacturing Podcasts
Continuous improvement is best started with management on board. Expert in the field, Jeff Hajek, describes the structure a company needs to support it. Jeff tells of creating a continuous improvement …
Lean Manufacturing, Kaizen, Kanban, Six Sigma, Continuous Improvement
Owners and managers—the bosses—don’t often like change. Try “continuous improvement” to improve safety and efficiency. Start with no budget, in a small area to prove it and catch their attention. First, …
5S, Lean Manufacturing, Workplace Safety, Facility Efficiency, Safety, Continuous Improvement
Lean safety is the result of implementing “lean” methodology. Lean makes businesses less wasteful, more efficient and more profitable. An efficient workplace is a safer workplace. Simultaneous increases in efficiency and …
5S, Lean Manufacturing, Floor Marking, Safety Signs, Workplace Safety, Facility Efficiency, Safety
Hazard labels give critical information. Labels are the glue that hold the whole safety system together. From manufacturing to office settings, proper labeling of hazards is important for employee safety, and …
5S, Lean Manufacturing, GHS, Pipe Marking, PPE, Labeling, Workplace Safety, Facility Efficiency, Hazcom, Safety
Industrial labels are cheaper to make in-house. And quicker. For a manufacturing, in a warehouse, or almost any work site, consider buying a quality industrial label printer. Think about about all …
5S, Lean Manufacturing, GHS, Arc Flash, Pipe Marking, Electrical Safety, Safety Signs, Labeling, Workplace Safety, Regulations & Compliance, Facility Efficiency, Safety