Lean Methodology is a framework that evolved from the Toyota Production System (TPS), developed by Sakichi Toyoda, his son Kiichiro Toyoda, and Toyota engineer Taiichi Ohno. TPS emerged from Toyota’s need to build efficient, globally competitive vehicles.
TPS is defined by the Toyota Way, which consists of two main pillars:
- Continuous Improvement
- Respect for People
One of the pioneers of TPS, Taiichi Ohno, described its genesis in his 1988 book Toyota Production System: Beyond Large-Scale Production:
“The Toyota production system was conceived and its implementation began soon after World War II, but it did not gain significant attention until the first oil crisis in 1973. Faced with zero growth, Japanese managers saw the results of Toyota's relentless focus on eliminating waste.”
Just-In-Time Production
The core of TPS is the absolute elimination of waste. Two pillars support this system:
- Just-in-time: The right parts arrive at the assembly line only when they are needed, minimizing inventory.
- Autonomation (automation with a human touch): Machines stop automatically when issues arise, ensuring quality control.
According to W. Edwards Deming, "The customer is the most important part of the production line."
Lean Production System
In a 1988 article in MIT Sloan Management Review, John Krafcik (former CEO of Waymo) coined the term “Lean” as part of the MIT International Vehicle Program. He described how Toyota's system outperformed Western manufacturers by adapting pure Fordism, leading to the concept of a lean production system.
These research findings were popularized in the 1991 book The Machine That Changed the World by James P. Womack. The book identified five key principles of Lean Thinking:
- Specify value by product.
- Identify the value stream.
- Make value flow without interruptions.
- Let the customer pull value.
- Pursue perfection.
Lean focuses on creating value with fewer resources and less waste through continuous experimentation and improvement.
Lean in Modern Industries
Lean principles have been widely adopted across industries beyond manufacturing, including:
- Lean Software Development
- Lean Entrepreneurship/Startup (Steve Blank/Eric Ries)
- Lean Engineering
- Lean Analytics
- Lean UX
The main goal of Lean is to eliminate waste and create efficient, customer-driven products.
In his 2021 autobiography, Invention: A Life, James Dyson highlighted how Lean principles guide Dyson’s product development:
“For me, and for all Dyson engineers, lean engineering and material efficiency are guiding principles. Using fewer materials means less energy in production, lighter products, and a more enjoyable user experience.”
How are you adopting Lean Principles in your business?
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