How to think in Lean way?

How to think in Lean way?
How to think in Lean way?

How to think in Lean way?


A principle driven, tool based philosophy that focuses on eliminating waste so that all activities/steps add value from the customers perspective.

Lean Thinking is all about continuous waste elimination !

Impact of Lean Thinking:

  • Higher Customer Satisfaction
  • Shorter Resolution time
  • Improved productivity
  • Zero Defects
  • Zero down time
  • Higher Quality
  • Lower Costs
  • Higher Employee Satisfaction

Benefits of Lean:

Basically Problem solving and Non value add reduction is basic requirement for Lean.
First-identify the problem
secondly-Solve it
Thirdly-Define it and present.

Below are few tool relevant to digital inductry:


Jidoka allows machines/processes to operate autonomously by shutting down automatically if an abnormality occurs. This prevents defective products from passing to the next process


“Pokayoke” refers to low-cost, reliable devices or innovations that:
- Prevent or detect errors by an employee or systems
- Detect defects in products and prevent further processing

5 S

Building Blocks for process discipline and control; 5S are as follows

  • Sort
  • Set-In Order 
  • Shine
  • Standardize
  • Sustain


A visual device (light) or pin-pan-pon that operators use to call attention to an abnormality. The use of this is to request immediate attention and action to the problem.


An arrangement of people, systems, items, and methods with the processing steps placed right next to each other (physically or digitally) in sequential order, through which parts are processed in a continuous flow.


Heijunka is the foundation of the Toyota Production system, and is the process of leveling and sequencing an operation.


A Kanban is a signal used by a downstream operation to request a material replenishment


Any type of waste elements that add no value to the product: i.e. Waiting, Transporting, Over production, Excess Motion, Inventory Defects, Human Touches.
JITJust in time) theory of production characterized by (1) single piece flow, (2) producing according to TAKT time, (3) pulling of material from upstream process, keeping inventory at minimum, established levels.


Continuous, Incremental Improvement Of An Activity To Create More Value With Less Waste (Muda).

What Qualifies for Lean project?

Below factors need to be analyzed before we take up a lean project.

  • Re-usability--if some work is repeatative and can be constructed as a block which can be re usable can be considered as a Lean.
  • Reducing manual job by automation--Yes...if you write a simple macro to automate a manual job that can also be treated as Lean.This is saving time...reduce manual intervention.
  • Rework reduction...again the same..
  • Proactive issue identification & Resolution
  • Automated report/Database preparation
  • Superfluous License/functionality/report elimination
  • Defect elimination at its source
  • Process simplification-
  • Eliminate Non value added steps
  • Process Standardization
  • Processing logic established- Parallel processing; Sequential processing; batch processing
  • Sorting; Prioritization; Visual/audio alert
  • Define clear activity & responsibility
  • Extra resource (H/W , People; S/W) avoidance

How to think in Lean way? How to think in Lean way? Reviewed by Animesh Chatterjee on August 16, 2009 Rating: 5

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