Lean Manufacturing – getting started, benefits, and the most common mistakes
Lean Manufacturing (lean production) is a management philosophy that says: eliminate everything that does not add value for the customer. No unnecessary inventory, no redundant steps, no waiting. In practice, it is about “slimming down” processes so that a company produces faster, cheaper, and smarter.
The idea originated in Japan, mainly at Toyota, and then spread worldwide. But don’t worry—Lean is not only for car factories. It is a mindset that can be implemented in almost any industry.
Why do companies choose Lean Manufacturing?
- Lower costs – less inventory, fewer downtimes, fewer reworks.
- Higher quality – problems surface earlier, before they affect thousands of products.
- Better flow – processes are simpler and easier to control.
- Higher customer satisfaction – customers get exactly what they want, faster than from competitors.
- Engaged teams – Lean is based on the idea that everyone can contribute improvement ideas.
👉 See also: Production automation with Odoo – is it worth it and how much does it cost?
What does Lean look like in practice?
Lean focuses on eliminating so-called “muda”, meaning waste. Traditionally, seven types are identified:
- Overproduction – producing more than the customer needs.
- Waiting – people or machines standing idle, waiting for materials.
- Transportation – unnecessary movement of goods between locations.
- Overprocessing – doing more work than required (e.g. excessive formalities).
- Inventory – excess work-in-progress and materials.
- Motion – unnecessary movement of employees.
- Defects – errors that require rework.
Often, an eighth type is added: unused human potential. If employees see problems but no one listens, you lose valuable improvement opportunities.
Real-life examples
- Electronics factory – instead of holding three months of component inventory, it operates in a Just in Time model with daily deliveries.
- Furniture manufacturer – reduced internal transport by arranging machines according to the process flow instead of moving parts around the shop floor.
- Printing house – implemented a quality system that detects errors after the first defective copy, not after 500.
The most common mistakes when implementing Lean
- Confusing Lean with cost-cutting – it’s not about laying people off, but about smarter processes.
- Moving too fast – changing the entire factory at once leads to chaos. It’s better to start with one area.
- Lack of management support – if leaders don’t believe in Lean, the team won’t either.
- Ignoring employees – Lean relies on their ideas. Without them, it’s just a slogan.
- Lack of supporting systems – Lean with data in Excel will not last long. You need an ERP system, such as Odoo ERP.
👉 See also: 10 tasks that Odoo will automate for you.
How to get started with Lean Manufacturing?
- Map your processes. Identify where you really lose time and money.
- Engage your people. They know best where waste occurs.
- Implement small changes. One area, one line, one process at a time.
- Measure results. Track time, cost, and quality—without metrics, you don’t know if Lean works.
- Leverage technology. Automation, WMS, reporting—without these, Lean remains theory.
Frequently asked questions
Does Lean work only in manufacturing?
No. Lean can also be applied in services, IT, and administration.
Does Lean mean reducing headcount?
No. The goal is for people to focus on value-adding work, not repetitive, pointless tasks.
Where should I start Lean in my company?
Ideally with process analysis and a pilot in one area. From there, it can be scaled further.
