Lean thinking is an approach to optimizing business processes that focuses on customer satisfaction and waste reduction. In this article, you will learn about the basics of lean thinking, its development and the key principles that help companies become more efficient and successful - both for lean management in general, which is also at the heart of lean thinking - as well as lean thinking's own principles as an overarching management philosophy.

The most important facts at a glance

• Lean thinking is a holistic management philosophy that minimizes waste and makes customer value achievable while conserving resources. The focus is always on the needs of the customer, with the continuous improvement of processes taking center stage.

• Lean management forms the foundation of lean thinking and includes the five central principles for increasing efficiency and reducing waste. However, lean thinking goes beyond this and also integrates cultural and strategic aspects to enable a holistic transformation.

  • Customer needs as the starting point: Every optimization starts with the customer's needs. The principle is: "Always start from the need."

  • Promoting scientific thinking: Lean thinking creates an environment in which experimental and iterative learning becomes a habit. Continuous adaptation and learning from experience are central components of this way of thinking.

  • Empowering and involving employees: Lean thinking places great emphasis on the involvement of all employees and the development of skills to contribute to continuous improvement.

  • Systemic thinking: All processes and players are interconnected. Understanding the interrelationships helps to make optimizations systematically rather than in isolation.

• Lean thinking is not just a collection of tools, but a culture of continuous development that is reflected in daily learning, continuous improvement processes and an open error culture. This means that all employees regularly question their working methods, make suggestions for improvement and are actively involved in optimizing processes. Successful implementation requires committed managers who coach their employees to create an environment of continuous improvement.

What is Lean Thinking?

Lean thinking is a comprehensive management philosophy that aims to create the required value with fewer and fewer resources and less waste. The focus is always on the needs of the customer, with the continuous improvement of processes taking center stage. Lean thinking goes beyond pure lean management by establishing a way of thinking that must be deeply integrated into the corporate culture in order to achieve sustainable success.

Lean management represents the core of lean thinking and includes the five central principles that focus on increasing efficiency and reducing waste. Lean thinking, on the other hand, also encompasses an overarching philosophy that also affects the values, mindset and cooperation within the company. This way of thinking is aimed at systematic adaptability and the pursuit of perfection in all areas of the company.

But what exactly is behind this approach and how did it develop? The answer can be found in the history of the Toyota Production System, which serves as the basis for Lean Thinking. This system is based on the philosophy of eliminating waste and continuously improving processes.

Let's take a look at the origins and underlying philosophy to gain a deeper understanding of Lean Thinking.

Origin and philosophy of lean thinking

The origin: The Toyota production system

The concept of lean thinking has its roots in the Toyota production system, which was developed in Japan after the Second World War. In view of the shortage of raw materials, it was crucial for Toyota to use resources efficiently and minimize waste. Taiichi Ohno, one of the key developers of this system, focused on the elimination of waste and the continuous improvement of processes. These principles formed the basis for what we know today as the lean philosophy.

The philosophy behind lean thinking: promoting scientific thinking

Lean thinking creates an environment in which iterative experimentation and scientific thinking are encouraged to develop innovative solutions. This approach is often described as "navigating with a compass" - the direction is known, but the exact path is discovered through experimentation and continuous learning. This method enables companies to respond flexibly to change and continuously improve.

The pursuit of perfection and continuous improvement are at the heart of lean thinking. Through regular learning and adaptation, companies can optimize their processes and find innovative solutions that meet the needs of their customers.

Now that we understand how scientific thinking is encouraged in Lean Thinking, it's time to explore the specific principles that underpin this approach.

Lean Thinking principles

Lean Thinking also pursues extended guidelines that affect the company as a whole and support its cultural and strategic orientation:

1. Find out who your customers are

2. Determine the value from the end customer's perspective (understand customer requirements)

3. Identify all steps in the value chain and, if possible, eliminate those steps that do not create added value.

4. Ensure that the value-adding steps are carried out in close succession so that the product can flow smoothly to the customer.

5. When the flow is introduced, let customers deduct the value from the next upstream activity.

6. Reflect often with the goal of achieving perfection where perfect value is created without waste.

7. Take time to predict the future: Make forecasts, think ahead, conduct strategic analyses, set priorities (...)

These principles are not just theoretical concepts, but practical methods that have been successfully applied in various industries.

Eric Ries, a prominent advocate of lean thinking, puts it in a nutshell: "Lean thinking defines value as providing benefit to the customer; anything else is waste". This makes it clear that the focus should always be on the customer and their needs.

Let's now take a brief look at the five central principles of lean management, which also form the foundation of lean thinking. You can find much more information on this in our comprehensive guide to lean management.

The practical application of lean principles

The lean thinking principles provide a clear guideline for making processes more efficient and minimizing waste. But how do you put these principles into practice? Here are some approaches that can help you.

Find out who your customers are

Before you can create value, you need to know exactly who you are creating it for. Identify your target customers through market research, customer surveys and data analysis. Create detailed customer profiles or personas to understand their needs, wants and pain points. This knowledge enables you to develop products and services that are tailored to your customers.

Determine the value from the end customer's perspective

The first step is to really understand what your customers want. Conduct surveys, collect feedback and observe buying behavior. This way you can find out which aspects of your product or service offer the most value to the customer. Focus your resources on these areas to achieve maximum customer satisfaction.

Identify and eliminate non-value-adding steps in the value chain

Create a detailed flowchart of your processes. Mark each step and ask yourself whether it contributes directly to the end value for the customer. You should reconsider or eliminate steps that do not offer any added value. Tools such as value stream mapping can be very helpful here.

Ensure a smooth flow

Once you have removed unnecessary steps, optimize the sequence and execution of the remaining processes. The aim is to eliminate bottlenecks and enable a continuous flow. Methods such as just-in-time production or Kanban systems can improve the process flow.

Let the customer draw the value

Instead of producing products in stock, wait for the customer's signal before you produce. This pull principle prevents overproduction and inventory costs. Implement systems that are flexible enough to respond quickly to customer requests.

Reflect regularly and strive for perfection

Schedule regular meetings to review processes and identify opportunities for improvement. Use methods such as Kaizen to promote continuous improvement. Encourage your team to proactively make suggestions and be open to change.

Take time for strategic planning and foresight

In addition to optimizing current processes, it is important to take a look into the future. Create forecasts, carry out market analyses and set clear priorities. This will help you to position your company successfully in the long term and react to changes at an early stage.

The five principles of lean management as the cornerstone of lean thinking

The five central principles of lean management are:

1. Defining value from the customer's perspective

2. Analyze value stream

3. Create flow

4. Apply the pull principle

5. Striving for perfection

These principles can drive significant efficiency gains and cost reductions in a variety of sectors, from automotive to construction. Let's take a closer look at each of these principles and understand how they can help optimize business processes.

Defining value from the customer's perspective

The first step is to precisely define what is of value to the customer. Everything else is a waste.

Analyze value stream

Identify all steps of the value creation process and eliminate those that do not offer any added value.

Create flow

Ensure a continuous flow of value-adding steps to increase efficiency and speed.

Apply the pull principle

Only produce to customer demand to avoid overproduction and reduce storage costs.

Striving for perfection

Focus on continuous improvement in all areas (e.g. lean IT) in order to achieve perfect value creation without waste in the long term.

The role of management in lean thinking

Convinced management is crucial for the sustainable implementation of lean management. Leaders need to develop a clear vision that encompasses the company's overarching goal and lean principles. Lean thinking is designed to make better business decisions and establish a strong lean culture through a systematic approach. Lean production focuses on minimizing waste in order to increase production quality and reduce response times.

The active participation and empowerment of employees are central to the success of lean management. Managers should exemplify lean principles and train their employees in their application in order to promote a culture of continuous improvement.

Lean Leadership

Lean leadership focuses on empowering managers instead of just giving instructions. Managers should actively act as coaches and inspire their employees. Management takes on the role of a trainer, helping employees to develop scientific thinking and apply lean principles in their daily work.

This type of leadership requires managers to act as mentors and supporters to encourage employee engagement and establish a culture of continuous improvement.

Coaching and daily practice

Regular coaching is necessary to establish lean thinking as a permanent mindset in the company. Daily coaching helps employees to improve their skills and anchors lean thinking as a new mindset and culture in the company. Managers must act as mentors and supporters to encourage employee engagement and support continuous improvement.

Summary: Lean thinking as the key to success

Lean thinking offers a systematic approach to process optimization and continuous improvement that has proven itself in various industries. These principles promote a culture of continuous improvement and innovation that ensures the long-term success of a company.

Management plays a decisive role in the implementation of lean thinking by developing a clear vision, exemplifying lean principles and training employees in their application. Lean leadership and regular coaching are essential elements in anchoring lean thinking as a permanent mindset in the company. By applying these principles and practices, companies can optimize their processes, increase customer satisfaction and achieve a sustainable competitive advantage.

Go deeper: Implementing the lean philosophy (tools & methods)

Lean thinking is put into practice using a range of tools and methods aimed at making processes more efficient and promoting continuous improvement.

1. kaizen

Kaizen literally means "change for the better" and stands for the principle of continuous improvement. It is an ongoing process in which all employees are actively involved in gradually improving processes, products and services.

• Application: Employees are encouraged to regularly make suggestions for improvements.

• Advantage: Promotes a culture of commitment and proactive problem solving.

2. kanban

Kanban is a visual system for controlling production processes and material flows according to the pull principle. It uses cards or signals to indicate the need for replenishment or work steps.

• Application: Use of Kanban cards to visualize the status of tasks in real time.

• Benefit: Reduces overproduction and stocks, improves flow and responsiveness.

3. value stream mapping (value stream mapping)

Value stream mapping is a method for visualizing all the steps in a process, from receipt of the order to delivery of the end product.

• Application: Creation of diagrams that depict both value-adding and non-value-adding activities.

• Advantage: Identifies bottlenecks and waste, enables targeted improvements.

4. 5S

The 5S method is a systematic approach to workplace organization and standardization. The five "S's" stand for sorting, systematizing, cleaning, standardizing and self-discipline.

• Application: Implementation of order and cleanliness in the workplace.

• Benefit: Increases efficiency, safety and employee satisfaction.

5. poka-yoke

Poka-yoke are error avoidance mechanisms that aim to prevent unintentional errors in processes.

• Application: Use of devices or procedures that make errors impossible or immediately noticeable.

• Advantage: Improves quality, reduces rework and rejects.

6th Gemba

Gemba means "the actual place" and encourages managers to go directly to the place where things are happening in order to understand processes and recognize problems.

• Application: Regular tours of the production facility or work area.

• Advantage: Better decision-making through direct observation and employee interaction.

7th Hansei

Hansei is the practice of self-reflection for error analysis and continuous improvement.

• Application: After completion of projects or processes, a reflection is carried out to identify successes and opportunities for improvement.

• Advantage: Promotes learning from experience and prevents repetition of mistakes.

8. standardized work

Standardized work includes documentation and adherence to best known practices for each process.

• Application: Creation of work instructions and training of employees accordingly.

• Advantage: Ensures consistency and quality and makes it easier to identify deviations.

9th Heijunka

Heijunka stands for production balancing and aims to smooth out fluctuations in production.

• Application: Planning production in small, mixed batches instead of large batch sizes.

• Advantage: Reduces inventories, improves flow and responds more flexibly to customer demand.

10th Jidoka

Jidoka means automation with human intelligence. It enables machines and employees to stop the process immediately if a problem occurs.

• Application: Integration of sensors or mechanisms that stop operation in the event of faults.

• Advantage: Prevents errors from being passed on, improves quality and promotes problem solving at the source.

In addition to the technical tools, the cultural dimension is a decisive factor for the success of Lean Thinking.

1. respect for people

Respect for people is a central principle of Lean Thinking. It means viewing employees as the company's most valuable asset.

• Application: Involving employees in decision-making processes, valuing their ideas and promoting their development.

• Benefit: Increases motivation, commitment and promotes a positive working environment.

2. continuous learning and improvement

The culture of continuous learning encourages all members of the organization to constantly acquire new skills and share knowledge.

• Application: Provision of training, workshops and learning opportunities.

• Advantage: Increases adaptability and promotes innovation.

3. teamwork

Teamwork is essential to achieve the goals of lean thinking. It promotes collaboration across departmental boundaries.

• Application: Formation of cross-functional teams to solve complex problems.

• Advantage: Utilizes the diverse skills and perspectives of employees to achieve better results.