Get Connected LinkedIn facebook


Find out how to improve your work.


Bexcellence Site Map , Here you find all website pages.


Here you can join our E-zine and download our free tools and info..

Be an Expert

Become a contributing author and have your articles included on

Submit Your Question

You can ask your question here.

Lean Manufacturing

Lean manufacturing is a generic process management philosophy derived mostly from the Toyota Production System (TPS) but also from other sources. Toyota's steady growth from a small player to the most valuable and the biggest car company in the world made Lean a hot topic in management science. In order to improve overall customer value, the Lean approach focuses on the reduction of the original Toyota 8 wastes.

Lean benefits




10 to 20% gains in capacity by optimizing bottlenecks


Reductions of 30 to 40% in inventory

Cycle time

Throughput time reduced by 50 to 75%

Lead time

Reduction of 50% in order fulfillment

Product development time

Reductions of 35 to 50% in development time


35 to 50% space reduction

First-pass yield

5 to 15% increase in first-pass yield


Delivery performance of 99%

Lean manufacturing

Lean and DMAIC picture above from Lean Sigma Institute

Five principles of lean:

Principle 1: Accurately specify the value from the customer's perspective for both products and services.

Principle 2: Identify the value stream for products and services and remove any non-value-added waste along the value stream.

Principle 3: Make the product and services flow without interruption across the value stream.

Principle 4: Authorize production of products and services based on the pull from the customer.

Principle 5: Strive for perfection by constantly removing layers of waste.

Lean Tools

Lean is the set of  'tools' that assist in the identification and steady elimination of waste (muda), the improvement of quality, and production time and cost reduction. Below is a picture and links to some of the common Lean Tools.

Lean manufacturing










Lean Thinking

Overall Equipment Effectiveness



Takt Time

Theory of Contraints

Total Productive Maintenance

Value Stream Mapping

Table of Waste Categories

Another Lean Approach

There is a second approach  to Lean Manufacturing that is promoted by Toyota. This focuses's upon implementing the smoothing the flow (opposite of mura, unevenness) through the system and not upon 'waste reduction'.  Techniques to improve flow include production leveling, pull production (by means of kanban) and the Heijunka box.

After leaning about Lean manufacturing click here to see other process improvement tools.

Have A Question About This Topic?

Do you have a question about this? Share it!

[ ? ]

Upload 1-4 Pictures or Graphics (optional)[ ? ]


Click here to upload more images (optional)

Author Information (optional)

To receive credit as the author, enter your information below.

(first or full name)

(e.g., City, State, Country)

Submit Your Contribution

 submission guidelines.

(You can preview and edit on the next page)

What Other Visitors Have Said

Click below to see contributions from other visitors to this page...

Lean Principles
I’d like to know is there standard for lean principles, techniques and tools? In some sites read about standard SAE J4000, 4001, but I don’t know how …

Shining is to make problems obvious!
 Not rated yet
With clutter gone and the storage area organized, the next step is to properly and thoroughly clean and paint equipment and work areas. This step is critical …

Process Line Balancing
 Not rated yet
How to Consider the Line balace in New Line and Old Line and what basis we could consider it , What is the Percentage level of good line whether it has …

Lean Operation
 Not rated yet
In lean operation stock at best is describe as waste and stock at worse is regarded as evil.Dicuss.

Takt Time and Coatings Manufacture
 Not rated yet
I wish to know of any examples of Coatings Manufacturers using the concept of Takt time and if those examples could be shared with me urgently please!

3 C'S - Concern, Cause, Countermeasure Not rated yet
Give some guideline on 3 C'S - Concern, Cause, Countermeasure programme

Click here to write your own.