What Is Lean Manufacturing?
Lean manufacturing takes the old saying 'waste not, want not' and applies it as a blueprint for smarter, more efficient production. Toyota pioneered this approach in the 1950s, and today, businesses across the world use it to streamline their processes and cut waste. The goal is simple: eliminate anything that doesn’t add value to the final product.
What Are the Key Principles of Lean Manufacturing?
Lean manufacturing is based on five main principles that help companies improve production while reducing waste. Let’s break them down:
Identify Value
The first step in lean manufacturing is figuring out what customers actually want. What makes a product useful to them? Is it durability, speed, or cost? Anything that doesn’t contribute to said value is considered waste and should be reduced or, even better, removed. The goal is to make sure every step in production is helping to deliver what really matters.
Map the Value Stream
Once you know what’s valuable, the next step is to look at the entire production process and pinpoint where waste happens. This is called value stream mapping. It helps flag delays, unnecessary steps, and anything else that slows things down. Once these areas of waste are identified, it's time to start trimming the fat.
Create Flow
Next up is breaking down each part of the process to make sure everything moves smoothly, with parts and materials transitioning easily from one step to the next without delays. This can involve training employees, adjusting production workflows, and incorporating automation like robotics and AI to improve efficiency.
Establish Pull
Instead of making large batches based on predictions, lean manufacturing uses a pull system—producing only when there’s actual demand. This prevents overproduction, reduces excess inventory, and keeps production responsive. A pull-based approach means companies manufacture what’s needed, when it’s needed, avoiding wasted materials and unnecessary costs.
Seek Perfection
Lean isn’t a quick fix—it’s a mindset of constant improvement. Businesses should keep looking at how they are doing things, listening to employee feedback, and making small changes to get even better results.
What Are the Benefits of Lean Manufacturing?
- Lean manufacturing makes businesses more flexible, efficient, and responsive to customer demands.
- Flexibility: Lean keeps production adaptable, so businesses can react quickly to market changes.
- Efficiency: Simpler processes move products through production faster with less waste.
- Quality: Regularly fine-tuning production leads to fewer defects, more consistent results, and better products overall.
- Cost savings: Less waste means less money, with lower costs across the board.
- Sustainability: A manufacturing approach that uses only what’s needed results in a smaller environmental footprint.
What Are the Main Types of Waste in Lean Manufacturing?
Lean manufacturing points to eight areas where waste tends to build up.
- Overproduction: Making more than needed.
- Waiting time: Delays between production steps.
- Unnecessary motion: Extra movement that doesn’t add value.
- Excess inventory: Storing more materials or products than necessary.
- Defects: Errors that require fixing or scrapping.
- Over-processing: Doing extra work that isn’t required.
- Unutilised talent: Failing to make the most of employees’ skills.
- Transportation waste: Moving products and materials more than necessary.
How Does Lean Manufacturing Work?
Lean manufacturing works by analysing workflows and cutting waste at every step. Using strategies like just-in-time production, standardisation, and automation, lean keeps operations running as smoothly as possible. Different industries and technologies tailor the application of lean principles to meet each specific need.
Lean by Technology
The tools and techniques used for lean manufacturing also vary: injection moulding is ideal for large-scale lean manufacturing, while CNC machining and 3D printing enable rapid prototyping and small-batch production.
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Injection moulding: Great for high-volume production, injection moulding produces consistent parts quickly while keeping material waste low.
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CNC machining: Reduces waste by automating precision cutting, eliminating human error, and optimising material use.
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3D printing: Supports lean through rapid iteration, allowing companies to refine designs without mass production waste.
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Sheet metal fabrication: Helps manufacturers produce only what’s needed by using lean-friendly, on-demand production methods.
What Are the Biggest Challenges of Implementing Lean Manufacturing?
Switching to lean manufacturing isn’t always easy. It requires companies to rethink the way they work, which can take time and effort.
- Resistance to change: Employees and managers may be hesitant.
- Upfront costs: Training and restructuring require investment.
- Complexity: Large operations can be harder to streamline.
- Balancing efficiency and flexibility: Lean should improve workflow without becoming too rigid. Process for process’s sake isn’t helpful.
How Has Lean Manufacturing Changed Over Time?
Lean manufacturing has come a long way since the 1950s. Quickly expanding beyond the Toyota factory floor, it was widely adopted across industries such as aerospace, medical devices, and consumer electronics. Companies have refined lean practices using new tools like Six Sigma, automation, and real-time data monitoring to make operations even more efficient. The biggest evolution in lean manufacturing has been the introduction and integration of new digital technologies. Automation, robotics, AI-driven analytics, and predictive maintenance now allow manufacturers to optimise workflows, reduce human error, and cut lead times.
The rise of on-demand manufacturing platforms, like Protolabs, has also transformed lean manufacturing. Founded in 1999, Protolabs pioneered online manufacturing, allowing companies to rapidly prototype and produce parts with minimal waste. Today, Protolabs also offers instant access to a highly vetted global network of manufacturing partners, further expanding capacity while speeding up workflows.
How Does on-Demand Manufacturing Support Lean Principles?
On-demand manufacturing is one of most effective tools in the lean utility belt. Producing only what’s needed, when it’s needed, helps businesses avoid overproduction, lower costs, and stay flexible.
- Just-in-time production: Reduces excess inventory.
- Rapid prototyping: Allows fast design iterations.
- Optimised supply chains: Uses digital manufacturing and AI to match production with real demand.
As an on-demand manufacturing platform, Protolabs unlocks a variety of lean principles for engineers. With automated quoting, digital workflows, and rapid production, we help companies adopt a leaner, more streamlined manufacturing process.
FAQs About Lean Manufacturing
How is lean different from Six Sigma?
Lean manufacturing focuses on eliminating waste and streamlining production so that every step adds value. Six Sigma, on the other hand, is mostly about reducing variation and defects to improve product quality. Many businesses combine both—lean to optimise workflows and Six Sigma to enhance precision and consistency.
What are the 5 M's of lean manufacturing?
The 5 M’s refer to manpower, machines, materials, methods, and measurement. These are key factors to evaluate when trying to identify possible areas of waste.
Can lean be applied to low-volume production?
Yes, lean works for both mass production and lower-volume custom manufacturing by stepping up efficiency at every level.
How does lean manufacturing impact supply chains?
It reduces excess inventory, improves supplier coordination, and boosts overall efficiency in the supply chain.
What are some real-world examples of lean manufacturing?
Toyota revolutionised manufacturing with its just-in-time system, Amazon applies a lean, automated approach in its fulfilment centres, and Protolabs brings lean to digital manufacturing, enabling fast, on-demand production.
Get a Quote for Lean Manufacturing
Protolabs helps companies apply lean manufacturing principles with digital production.
- Rapid prototyping with CNC machining and 3D printing.
- Low-volume production to reduce waste and costs.
- Rapid injection moulding for lean, high-efficiency part production.
- Automated workflows for fast, efficient manufacturing.
Make manufacturing leaner, faster, and more efficient. Upload your designs to get a free, instant quote.