Many business processes and especially manufacturing are based on serial processes, where things are passed down a chain of processes, with value being added at each point. Within this system there is massive opportunity for inefficiency and waste, such as buffer stores, things getting lost, breakdowns, etc.
A lean system has none of this fat. Going lean means removing all waste from the system. This has many implications, such as:
- Gaining a true understanding how things work so you can constantly improve, reduce waste and increase efficiency.
- Reducing buffer storage to the absolute minimum, which makes everything connected: if one point in the system breaks down, everyone is very rapidly also affected.
- Attention to bottlenecks, including when up-stream to suppliers and downstream to customers.
- Being able to rapidly change the system to work on different products.
- Having flexible, multi-skilled people who can perform such changes.
- Having systems and management that engenders such a capable and motivated workforce.