{"id":1126,"date":"2025-08-28T16:40:40","date_gmt":"2025-08-28T14:40:40","guid":{"rendered":"https:\/\/nexelem.com\/en\/?post_type=blog&#038;p=1126"},"modified":"2026-03-24T21:44:05","modified_gmt":"2026-03-24T20:44:05","slug":"what-is-lean-manufacturing","status":"publish","type":"blog","link":"https:\/\/nexelem.com\/en\/blog\/what-is-lean-manufacturing\/","title":{"rendered":"What is lean manufacturing?"},"content":{"rendered":"\n<p>In times when high competitiveness is of particular importance, a manufacturing company should have the key ability to reduce operating costs while simultaneously increasing efficiency. This need has led to the development of many new management concepts, one of the most popular methods being lean manufacturing. <strong>To fully understand lean manufacturing meaning, many managers still ask what is lean manufacturing and what does lean manufacturing mean in practical, operational terms.<\/strong> And how does it affect the increase in competitiveness of manufacturing enterprises?<\/p>\n\n\n\n<nav>\n  <h2>Table of Contents:<\/h2>\n  <ul>\n    <li><a href=\"#lean-manufacturing-definition\">Lean manufacturing \u2013 lean manufacturing definition and philosophy<\/a><\/li>\n    <li><a href=\"#history-assumptions\">History and main assumptions of lean manufacturing<\/a><\/li>\n    <li><a href=\"#goals\">Goals of the lean manufacturing concept<\/a><\/li>\n    <li><a href=\"#tps-methods\">TPS methods and techniques<\/a><\/li>\n    <li><a href=\"#lean-tools\">Lean manufacturing tools \u2013 examples<\/a><\/li>\n    <li><a href=\"#characteristics-lean-thinking\">Characteristics of the Lean Thinking philosophy<\/a><\/li>\n    <li><a href=\"#lean-vs-lean-management\">Lean Management vs. Lean Manufacturing \u2013 differences<\/a><\/li>\n  <\/ul>\n<\/nav>\n\n\n\n<h2 id=\"lean-manufacturing-definition\">Lean manufacturing \u2013 lean manufacturing definition and philosophy<\/h2>\n\n\n\n<p>The concept of lean manufacturing is based on management that improves the quality of products and processes and eliminates waste. <strong>In simple terms, what is meant by lean manufacturing is creating more value for the customer while using fewer resources across the entire production system.<\/strong> Lean means less human effort, less space in the plant, fewer tools, half the investment, and time to design a product manufactured twice as fast. It involves eliminating unnecessary activities and performing necessary ones in the correct sequence. <strong>This explanation is often used when defining what does lean manufacturing mean for modern factories operating under cost pressure.<\/strong><\/p>\n\n\n\n<p>Activities consistent with the philosophy of lean manufacturing make it possible to reduce the consumption of everything needed in the production process. As a result, we get a product better suited to customer needs and additionally manufactured at a much lower cost compared to mass production. The concept of lean manufacturing, therefore, consists of improving the operation of the production system by eliminating all kinds of waste to produce exactly as much as customers need. <strong>This concept of lean production directly supports flexibility, responsiveness, and long-term competitiveness.<\/strong> Every unsold product is treated as a loss.<\/p>\n\n\n\n<h2 id=\"history-assumptions\">History and main assumptions of lean manufacturing<\/h2>\n\n\n\n<p>Although elements of lean production were used as early as the 16th century, the automotive company Toyota is considered the precursor of the concept of lean manufacturing. In the 1940s, Japanese engineer Taiichi Ohno began a series of changes in production organisation. These activities transformed Toyota from a local factory into a global leader in the automotive industry. The production system introduced became an alternative to the model of mass production. Interestingly, the tools and techniques used were discovered and described relatively late, only in the 1980s, when the automotive crisis in the United States intensified due to the growing competitiveness of Japanese manufacturers. The result of investigating the causes of the crisis was the 1990 book \u201cThe Machine That Changed the World,\u201d in which the concept of lean manufacturing was described for the first time. <strong>This publication helped clarify the lean manufacturing meaning for Western managers and academics.<\/strong><\/p>\n\n\n\n<p><strong>The most commonly used graphical form that presents a summary of the most important assumptions of lean production is the so\u2011called Toyota Production System (TPS) house.<\/strong><\/p>\n\n\n<div class=\"wp-block-image\">\n<figure class=\"aligncenter size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"502\" src=\"https:\/\/nexelem.com\/en\/wp-content\/uploads\/sites\/2\/2025\/08\/The-TPS-House_min-1024x502.png\" alt=\"Toyota Production System House - infographic\" class=\"wp-image-1199\" srcset=\"https:\/\/nexelem.com\/en\/wp-content\/uploads\/sites\/2\/2025\/08\/The-TPS-House_min-1024x502.png 1024w, https:\/\/nexelem.com\/en\/wp-content\/uploads\/sites\/2\/2025\/08\/The-TPS-House_min-300x147.png 300w, https:\/\/nexelem.com\/en\/wp-content\/uploads\/sites\/2\/2025\/08\/The-TPS-House_min-768x377.png 768w, https:\/\/nexelem.com\/en\/wp-content\/uploads\/sites\/2\/2025\/08\/The-TPS-House_min.png 1281w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><\/figure><\/div>\n\n\n<p>The TPS house consists of elements such as:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>the roof, i.e., the company\u2019s goals,<\/li>\n\n\n\n<li>the pillars, thanks to which the goals are achieved,<\/li>\n\n\n\n<li>the foundations, which constitute the assumptions and practices of the entire company.<\/li>\n<\/ul>\n\n\n\n<p>In the simplest terms, it is assumed that to achieve the goal (in this case, the roof), you must start by building solid foundations on which to place the appropriate pillars. It is also assumed that the improper functioning of any element in the system weakens the entire structure.<\/p>\n\n\n\n<p><strong>Currently, the lean manufacturing definition goes beyond the scope of Toyota\u2019s production system<\/strong>, which makes it possible to adapt it to enterprises with a different operating profile. <strong>This broader view explains what is lean manufacturing today, not as a single methodology but as a scalable management approach.<\/strong> Lean is now a more universal model described in three categories:<\/p>\n\n\n<div class=\"wp-block-image\">\n<figure class=\"aligncenter size-full\"><img loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"513\" src=\"https:\/\/nexelem.com\/en\/wp-content\/uploads\/sites\/2\/2025\/08\/Lean-concept_min.png\" alt=\"Lean Concept - infographic\" class=\"wp-image-1202\" srcset=\"https:\/\/nexelem.com\/en\/wp-content\/uploads\/sites\/2\/2025\/08\/Lean-concept_min.png 1024w, https:\/\/nexelem.com\/en\/wp-content\/uploads\/sites\/2\/2025\/08\/Lean-concept_min-300x150.png 300w, https:\/\/nexelem.com\/en\/wp-content\/uploads\/sites\/2\/2025\/08\/Lean-concept_min-768x385.png 768w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><\/figure><\/div>\n\n\n<h2 id=\"goals\">Goals of the lean manufacturing concept<\/h2>\n\n\n\n<p>SQDC is an acronym defining the main goals of lean manufacturing:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>S &#8211; Safety<\/li>\n\n\n\n<li>Q &#8211; Quality<\/li>\n\n\n\n<li>D &#8211; Delivery<\/li>\n\n\n\n<li>C &#8211; Costs<\/li>\n<\/ul>\n\n\n\n<p><strong>These goals of lean manufacturing reflect the balance between operational excellence and employee well-being, which is essential for sustainable performance.<\/strong><\/p>\n\n\n\n<p>Enterprises consistent with the lean philosophy also strive to eliminate the so\u2011called <strong>3 Mu, i.e., Mura (unevenness), Muri (overburden), and Muda (waste)<\/strong>. These factors are interrelated, which can pose numerous problems in an enterprise. For example, unevenness of deliveries from suppliers or variability in production plans can cause inefficient use of human and machine resources, which may stand idle or work at too fast a pace. Excessive overburden leads to quality declines and more errors.<strong> In the context of lean manufacturing, the most attention is focused on Muda, i.e., waste, which is very often visible in production processes.<\/strong> Currently, eight basic types are distinguished, of which Taiichi Ohno identified the first seven.<\/p>\n\n\n\n<p>These are:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Overproduction<\/strong> \u2013 when the quantity of goods or services produced exceeds customer demand. This is currently presented as the most significant type of waste.<\/li>\n\n\n\n<li><strong>Production defects <\/strong>\u2013 the product does not meet customer requirements, necessitating corrections or part scrapping.<\/li>\n\n\n\n<li><strong>Excess inventory<\/strong> \u2013 storing too many materials in the company, i.e., raw materials, semi\u2011finished products, spare parts. In the office, there are excessive amounts of received emails, printed documents, and office supplies.<\/li>\n\n\n\n<li><strong>Waiting<\/strong> \u2013 caused by material shortages, non\u2011functioning IT systems, breakdowns, and machine changeovers.<\/li>\n\n\n\n<li><strong>Over\u2011processing<\/strong> \u2013 focusing on activities that do not increase product value, e.g., excessive machining of parts.<\/li>\n\n\n\n<li><strong>Transport <\/strong>\u2013 concerns the distances that products, semi\u2011finished products, or tools travel between, for example, the warehouse and the workstation.<\/li>\n\n\n\n<li><strong>Unnecessary motion<\/strong> \u2013 unnecessary movements must be made to complete a task.<\/li>\n\n\n\n<li><strong>Lost employee creativity <\/strong>\u2013 a situation in which the ideas of members of the organisation are ignored. Task repetition enables an employee to become an expert in a given field, which can then be leveraged to improve processes.<\/li>\n<\/ul>\n\n\n\n<h2 id=\"tps-methods\">TPS methods and techniques<\/h2>\n\n\n\n<p><strong>Lean manufacturing currently provides a pervasive system of tools<\/strong> aimed at eliminating the 3 Mu, i.e., waste, unevenness, and overburden of employees. This practical side of lean management in manufacturing translates strategy into daily operational discipline. Some methods come from the Toyota Production System, which, along with the popularisation of the lean concept, has been expanded with additional techniques.<\/p>\n\n\n\n<p>The classification of tools was defined by M. \u0106wikli\u0144ski and H. Obra, who introduced a division into those that serve:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Improving organisation<\/strong>, e.g., JIT (Just In Time), internal pull system\/supermarkets \u2013 Kanban system, One Piece Flow, 5S, TPM, Standardised Work, Production Levelling (heijunka), Jidoka, Self\u2011inspection at the workstation, Teamwork, Nemawashi decision\u2011alignment system, Kaizen, Hoshin Kanri.<\/li>\n\n\n\n<li><strong>Problem-solving<\/strong>, e.g., Andon, Poka\u2011Yoke, problem\u2011solving at the point of occurrence (Genchi Genbutsu), Brainstorming, PDCA, Pareto charts, Ishikawa diagram, 5 Whys.<\/li>\n<\/ul>\n\n\n\n<p>However, it should be remembered that simply using lean production tools will not make a company operate according to this concept.<strong> Understanding what is meant by lean manufacturing requires a cultural shift, not only procedural changes. It is necessary to make more profound changes by implementing the philosophy of Lean Thinking.<\/strong><\/p>\n\n\n<div class=\"wp-block-image\">\n<figure class=\"aligncenter size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"503\" src=\"https:\/\/nexelem.com\/en\/wp-content\/uploads\/sites\/2\/2025\/08\/Examples_min-1024x503.png\" alt=\"Example of Lean Manufacturing Tools - infographic\" class=\"wp-image-1204\" srcset=\"https:\/\/nexelem.com\/en\/wp-content\/uploads\/sites\/2\/2025\/08\/Examples_min-1024x503.png 1024w, https:\/\/nexelem.com\/en\/wp-content\/uploads\/sites\/2\/2025\/08\/Examples_min-300x147.png 300w, https:\/\/nexelem.com\/en\/wp-content\/uploads\/sites\/2\/2025\/08\/Examples_min-768x377.png 768w, https:\/\/nexelem.com\/en\/wp-content\/uploads\/sites\/2\/2025\/08\/Examples_min.png 1280w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><\/figure><\/div>\n\n\n<h2 id=\"lean-tools\">Lean manufacturing tools \u2013 examples<\/h2>\n\n\n\n<p><strong>5S tool<\/strong> \u2013 used to create an optimal workplace through:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Seiri (sort, selection): identifying and removing all unnecessary items at the workstation.<\/li>\n\n\n\n<li>Seiton (set in order, systematisation): designating places for all items to limit unnecessary motion and effort.<\/li>\n\n\n\n<li>Seiso (shine, cleaning): keeping workstations clean by defining who, when, and what to do.<\/li>\n\n\n\n<li>Seiketsu (standardize): developing and implementing standards for the first three steps of 5S\u2014these should be simple and visual.<\/li>\n\n\n\n<li>Shitsuke (sustain, self\u2011discipline): maintaining implemented improvements at the workstation by constantly promoting 5S in the workplace, communicating results, and training employees.<\/li>\n<\/ul>\n\n\n\n<p><strong>Kaizen <\/strong>\u2013 continuous improvement by constantly introducing changes and enhancements through small steps. The goal is to shorten process lead time and improve quality. <strong>The rule is the involvement of employees at all levels. <\/strong>The thought process occurs at every stage of production, i.e., it is a response to the traditional approach to mass production. It strives to reduce costs and improve the ergonomics of workstations.<\/p>\n\n\n\n<p><strong><a href=\"https:\/\/nexelem.com\/en\/kanban-view\/\">Kanban<\/a><\/strong> \u2013 in Japanese, means a visual board. This method involves controlling production through events that occur directly on the shop floor. The benefits of the tool include short processing time, low inventory, on-time delivery, and quality control at all stages of production.<\/p>\n\n\n\n<p><strong>SMED <\/strong>\u2013 sets a goal to reduce machine changeover time to a maximum of 10 minutes.<\/p>\n\n\n\n<h2 id=\"characteristics-lean-thinking\">Characteristics of the Lean Thinking philosophy<\/h2>\n\n\n\n<p><strong>A key element of lean manufacturing is the Lean Thinking philosophy.<\/strong> According to it, the elimination of waste is not an end in itself, but the setting of a path along which the enterprise should move. This mindset explains what does lean manufacturing mean beyond tools and metrics, as it focuses on continuous learning and improvement. This thinking is not about implementing more and more methods and tools; the key is to strive for excellence by shaping the right attitudes among employees. These principles are presented as a five\u2011step process:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>Define value<\/strong> \u2013 correctly define all activities performed by the company for which the customer is willing to pay. Eliminate those that do not add value, i.e., are waste.<\/li>\n\n\n\n<li><strong>Identify the value stream<\/strong> \u2013 the flow of materials and information through all parts of the enterprise, from order to product delivery, should be controlled to ensure that every activity in a specific department adds value.<\/li>\n\n\n\n<li><strong>Create flow <\/strong>\u2013 optimise activities to achieve a stable flow. Eliminate downtime, waiting between processes, and any disturbances.<\/li>\n\n\n\n<li><strong>Establish pull <\/strong>\u2013 the pull system should connect product manufacturing with demand so that production processes occur at a matched pace and in required quantities.<\/li>\n\n\n\n<li><strong>Pursue perfection <\/strong>\u2013 assumes that the company\u2019s improvement process is continuous; thus, we achieve higher quality, lower costs, and shorter delivery times.<\/li>\n<\/ul>\n\n\n\n<p>In addition to the methods and tools used to manage production, Toyota placed great emphasis on developing organisational culture. Building values and the right attitudes among employees is what distinguishes this Japanese company from competitors who introduced the Toyota production system.<strong> The advantage of lean manufacturing over other management styles did not lie in a set of tools, but in a specific philosophy of thinking and acting.<\/strong><\/p>\n\n\n\n<h2 id=\"lean-vs-lean-management\">Lean Management vs. Lean Manufacturing \u2013 differences<\/h2>\n\n\n\n<p>Although these terms sound similar, they refer to different areas of a company\u2019s operation. What differentiates the two concepts is the scope of activities undertaken. <strong>Lean Management is broader and involves improving the functioning of the enterprise in all its areas\u2014from production, through the sales department, to accounting and controlling. <\/strong>It assumes that the enterprise operates properly when the harmonious operation of all these elements is ensured. <strong>The goal of lean manufacturing is also the continuous development<\/strong> and improvement of operations; however, its scope is much narrower. It focuses primarily on the activities of operational (production) departments, while other areas such as accounting or procurement take a back seat.<\/p>\n\n\n\n<p>Efficient production management is currently the basis for cost reduction in a manufacturing company. <strong>When correctly implemented, the concept of lean production supports data-driven decisions, operational transparency, and long-term competitiveness.<\/strong> The right system such as <a href=\"https:\/\/nexelem.com\/en\/aps-advanced-planning-and-scheduling-software\/\">APS software<\/a> allows you to plan multi-stage production,often visualised through an interactive <a href=\"https:\/\/nexelem.com\/en\/gantt-chart-view\/\">Gantt chart for production schedule<\/a> tracking, while ensuring its real-time monitoring.<\/p>\n\n\n\n        <section class=\"container-fluid block-faq-accordion large-margin\" id=\"acf-block-67fe5aa3785de\">\n            <div class=\"container\">\n\n                <div class=\"row\">\n\n                    \n                        <div class=\"col-12 block-section\">\n                            <h2 class=\"mb-0\">\n                                F.A.Q.                            <\/h2>\n                        <\/div>\n\n                    \n\n                    \n\n                    <div class=\"col-12 col-lg-10 block-section\">\n                        <div class=\"accordion\" id=\"faq-accordion-acf-block-67fe5aa3785de\">\n\n                            \n                                    <div class=\"card\">\n\n                                        <div class=\"card-header\" id=\"heading-1-acf-block-67fe5aa3785de\">\n                                            <div class=\"card-h2\">\n                                                <button class=\"card-title\" type=\"button\" data-toggle=\"collapse\" data-target=\"#collapse-1-acf-block-67fe5aa3785de\" aria-expanded=\"true\" aria-controls=\"collapse-1-acf-block-67fe5aa3785de\">\n                                                    What is lean manufacturing?                                                    <i class=\"fa-solid fa-chevron-down\"><\/i>\n                                                <\/button>\n                                            <\/div>\n                                        <\/div>\n\n\n                                        <div id=\"collapse-1-acf-block-67fe5aa3785de\" class=\"collapse show\" aria-labelledby=\"heading-1-acf-block-67fe5aa3785de\" data-parent=\"#faq-accordion-acf-block-67fe5aa3785de\">\n                                            <div class=\"block-description\">\n                                                Lean manufacturing, also known as lean production, is a management concept aimed at improving the quality of products and processes and eliminating waste by reducing unnecessary activities.                                            <\/div>\n                                        <\/div>\n\n                                    <\/div>\n\n                                \n                            \n                                    <div class=\"card\">\n\n                                        <div class=\"card-header\" id=\"heading-2-acf-block-67fe5aa3785de\">\n                                            <div class=\"card-h2\">\n                                                <button class=\"card-title\" type=\"button\" data-toggle=\"collapse\" data-target=\"#collapse-2-acf-block-67fe5aa3785de\" aria-expanded=\"false\" aria-controls=\"collapse-2-acf-block-67fe5aa3785de\">\n                                                    What are the goals of the lean manufacturing concept?                                                    <i class=\"fa-solid fa-chevron-down\"><\/i>\n                                                <\/button>\n                                            <\/div>\n                                        <\/div>\n\n\n                                        <div id=\"collapse-2-acf-block-67fe5aa3785de\" class=\"collapse \" aria-labelledby=\"heading-2-acf-block-67fe5aa3785de\" data-parent=\"#faq-accordion-acf-block-67fe5aa3785de\">\n                                            <div class=\"block-description\">\n                                                The goals of lean manufacturing are cost reduction (K), improvement of product quality (J), and shortening delivery time (D), often referred to as SQDC.                                            <\/div>\n                                        <\/div>\n\n                                    <\/div>\n\n                                \n                            \n                                    <div class=\"card\">\n\n                                        <div class=\"card-header\" id=\"heading-3-acf-block-67fe5aa3785de\">\n                                            <div class=\"card-h2\">\n                                                <button class=\"card-title\" type=\"button\" data-toggle=\"collapse\" data-target=\"#collapse-3-acf-block-67fe5aa3785de\" aria-expanded=\"false\" aria-controls=\"collapse-3-acf-block-67fe5aa3785de\">\n                                                    What tools and techniques belong to lean manufacturing?                                                    <i class=\"fa-solid fa-chevron-down\"><\/i>\n                                                <\/button>\n                                            <\/div>\n                                        <\/div>\n\n\n                                        <div id=\"collapse-3-acf-block-67fe5aa3785de\" class=\"collapse \" aria-labelledby=\"heading-3-acf-block-67fe5aa3785de\" data-parent=\"#faq-accordion-acf-block-67fe5aa3785de\">\n                                            <div class=\"block-description\">\n                                                Lean Management is a broader concept covering all areas of the company, aiming for harmonious operation. Lean Manufacturing focuses primarily on improving production departments by eliminating waste.                                            <\/div>\n                                        <\/div>\n\n                                    <\/div>\n\n                                \n                            \n                                    <div class=\"card\">\n\n                                        <div class=\"card-header\" id=\"heading-4-acf-block-67fe5aa3785de\">\n                                            <div class=\"card-h2\">\n                                                <button class=\"card-title\" type=\"button\" data-toggle=\"collapse\" data-target=\"#collapse-4-acf-block-67fe5aa3785de\" aria-expanded=\"false\" aria-controls=\"collapse-4-acf-block-67fe5aa3785de\">\n                                                    What are the stages of the Lean Thinking philosophy?                                                    <i class=\"fa-solid fa-chevron-down\"><\/i>\n                                                <\/button>\n                                            <\/div>\n                                        <\/div>\n\n\n                                        <div id=\"collapse-4-acf-block-67fe5aa3785de\" class=\"collapse \" aria-labelledby=\"heading-4-acf-block-67fe5aa3785de\" data-parent=\"#faq-accordion-acf-block-67fe5aa3785de\">\n                                            <div class=\"block-description\">\n                                                The stages of Lean Thinking are: define value, identify the value stream, create flow, establish pull, and pursue perfection. It aims for excellence and improvement through the right employee behaviours.                                            <\/div>\n                                        <\/div>\n\n                                    <\/div>\n\n                                \n                            \n                        <\/div>\n                    <\/div>\n\n                <\/div>\n\n            <\/div>\n        <\/section>\n\n    \n\n\n<p><\/p>\n","protected":false},"excerpt":{"rendered":"<p>In a highly competitive market, Lean Manufacturing is not just a methodology but a critical business strategy. It allows manufacturing companies to achieve two seemingly contradictory goals simultaneously: reducing operating costs and increasing efficiency. Adopting a Lean approach\u2014supported by modern digital tools\u2014enables companies to shorten delivery times, improve product quality, and significantly lower investment requirements. It is a shift from mass production to smart, flexible manufacturing that drives profitability through the relentless pursuit of perfection<\/p>\n","protected":false},"author":13,"featured_media":1197,"comment_status":"closed","ping_status":"closed","template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[11],"tags":[15,12,13],"class_list":["post-1126","blog","type-blog","status-publish","format-standard","has-post-thumbnail","hentry","category-production-management","tag-manufacturing-management","tag-production-cost-optimization","tag-production-planning"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v26.4 - https:\/\/yoast.com\/wordpress\/plugins\/seo\/ -->\n<title>What Is Lean Manufacturing? Concept and Goals | Nexelem \u2122<\/title>\n<meta name=\"description\" content=\"What is lean manufacturing? 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