Start with the basics

This quote always brings a smile because it rings so true. Mr. Shingo famously stated that the Toyota Production System consists of 80% waste elimination, 15% production system, and just 5% Kanban. Yet, so many self-proclaimed "Lean" companies jump straight to tools like Kanban before laying the groundwork. As a result, they often fail to achieve meaningful results and, sadly, abandon their Lean initiatives altogether.

The Toyota Production System and Lean thinking are not simply a toolbox; they are comprehensive, organization-wide strategies rooted in the principles of continuous improvement and respect for people. Together, they create a synergy that far surpasses the effectiveness of individual components.

Before any substantial improvements can take shape, companies must focus on creating and maintaining stability—establishing processes that consistently deliver value every day. Given that most work processes are rife with waste, organizations must prioritize engaging all team members in identifying waste and employing scientific thinking to eliminate it.

For this approach to succeed, employees need robust training in A3 problem-solving and a transparent system for suggesting improvement ideas that motivate and reward action. Regular daily huddles paired with visual boards can also enhance communication and accountability.

Eliminating waste fosters continuous flow, ensuring that value reaches the customer. It’s only when continuous flow is compromised that pull techniques like Kanban come into play. Start with the fundamentals, then introduce tools like Kanban when the time is right. Take your time now, so you can accelerate later. Embrace continuous improvement to drive sustainable growth.

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