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Definition

Lean is a management philosophy and improvement approach focused on maximizing customer value by eliminating waste, improving flow, and developing people. Rooted in the Toyota Production System (TPS), Lean emphasizes defining value from the customer’s perspective, understanding the Value Stream, reducing variation and delays, and enabling work to flow smoothly through a process.

Lean is more than a collection of tools. It is a socio-technical system supported by leadership behaviors, daily routines, and structured problem solving methods. Modern Lean practice includes the interconnected components of a Lean Management System, where the Strategy System, Daily Management System, and People System create a culture of continuous improvement and align daily actions to organizational purpose.

Lean principles apply across industries including manufacturing, healthcare, financial services, supply chain, and administrative functions. Lean principles often integrated with Six Sigma to enhance both speed and capability.

Examples

A healthcare clinic maps its patient intake Value Stream and discovers long delays caused by redundant data entry and inconsistent work handoffs. By applying Standard Work, visual scheduling, and daily huddles to coordinate flow, the clinic reduces patient wait time by 40% and improves overall satisfaction. Staff members also use A3 Problem Solving to address recurring issues and sustain the improvement.

Application

Organizations use Lean to:

Reduce waste (Muda), variation, and delays
Improve quality and reliability at the source (Jidoka)
Create predictable, stable processes through Standard Work
Increase transparency using visual management
Enable consistent performance through Daily Management routines
Build problem-solving capability among employees
Align improvement work with strategy and customer value

Lean can be applied within a DMAIC framework or alongside Lean Methods such as 5S, Kaizen, Kanban, or Poka-Yoke. These methods support the broader Lean philosophy and reinforce the behaviors and systems required to sustain improvement over time.