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“Lean-the key to World Class Manufacturing”


Lean is defined as a set of management practices to improve efficiency and effectiveness by eliminating waste. The core principle of lean is to identify, reduce and eliminate non-value adding activities and waste. Waste, or muda in Japanese, is defined as the performance of unnecessary work as a result of errors, poor organization, or communication. The typical MUDAs, as identified are:

  1. Transportation
  2. Inventory
  3. Motion
  4. Waiting
  5. Over-processing
  6. Over-production
  7. Defects
                model five principles of lean


Lean manufacturing improves efficiency, reduces waste, and increases productivity. The benefits, therefore, are manifold:

  • Increased product quality: Improved efficiency frees up employees and resources for innovation and quality control that would have previously been wasted.
  • Improved lead times: As manufacturing processes are streamlined, businesses can better respond to fluctuations in demand and other market variables, resulting in fewer delays and better lead times.
  • Sustainability: Less waste and better adaptability makes for a business that’s better equipped to thrive well into the future.
  • Employee satisfaction: Workers know when their daily routine is bloated or packed with unnecessary work, and it negatively affects morale. Lean manufacturing boosts not only productivity, but employee satisfaction.
  • Increased profits: And, of course, more productivity with less waste and better quality ultimately makes for a more profitable company.

Cost Reduction Through Lean Manufacturing


Manufacturing Organizations across the globe are facing stiffer competitions internally as well as from Manufacturing giants and are chasing the same customers in many cases. Be the best at what you do, or be ready to lose the business.

Knowing your customers’ expectations is crucial. Customers are focused on four things:

  • Product Variety
  • Reliable and Consistent Quality
  • Optimal Costs – value for money
  • On Time, In full, Error Free delivery

Customers demand the lowest price possible leaving very less to earn for the makers which directly reflects in the almost negated profits. They demand perfection and expect products that are totally defect-free. One other challenge that persists is that the demand is always urgent leaving the makers gasping for breather amidst their production cycles. The challenge for small companies is how to do all three of these well?

ADDVALUE, across two decades of consulting, has developed an exclusive approach to link Lean Practices with Business Goals and has hand held organizations towards becoming truly the great success stories. AVCI Consultants work closely with their clients to bring Lean Manufacturing (along with the in-house training of personnel in applicable concepts) into the Business Processes. ADDVALUE’s Lean model outlines the success mantra to approach Business Enhancement through Lean Manufacturing.

ADDVALUE’s TOTAL Lean Management Model - TLM

Lean is applied in manufacturing as Lean Manufacturing and as Lean Services in the service sectors. It is based on the TOTAL LEAN MANAGEMENT (TLM) Model.

  • TLM application is across the value chain, from supplier to end user
  • Objective is to increase the value-adding ratio - the ratio of the value adding (VA) to the total through put time (TPT)...focus on identification and reduction of non-value adding
  • Foundations of TLM are 5S and Top Management Commitment

TLM comprises of 5 pillars, which are dependent yet mutually exclusive.

                    model five principles of lean


Producing and moving one item at a time (or a small and consistent batch of items) through a series of processing steps as continuously as possible, with each step making just what is requested by the next step. It is also called the one-piece flow, single-piece flow, and make one, move one. The intent of flow production is to increase the velocity of products and make the production cycle predictable.

Lean Tools we use in TFM:

  • Spaghetti Diagram
  • Value Stream Mapping (VSM)
  • Product Quantity (PQ) Analysis
  • Flow Layout
  • 5S
  • Cellular Manufacturing
  • One Piece / Small Batch Flow
  • Standard Work In Progress (SWIP)

TFM Objectives:

  • Reducing material flow distance
  • Create Express Material Flow
  • Optimise Manpower
  • Reducing through Put time
  • Create Visual Plants


Total Productive Maintenance (TPM) is a system of maintaining and improving the integrity of production, safety and quality systems through the machines, equipment, processes, and employees that add value to the value chain.

Lean Tools we use in TPM:

  • 8 Pillars of TPM
  • Visual Machines
  • Spares Management
  • Reliability

TPM Objectives:

  • Zero Breakdowns
  • Zero Defects
  • Zero Accidents
  • Improving Equipment Availability
  • Reducing Cost of Manufacturing
  • Reducing Cost of Spares


Total Quality Management aims to make efforts to "install and make permanent climate where employees continuously improve their ability to provide on demand products and services that customers will find of particular value”.

Lean Tools we use in TQM:

  • 7 Basic QC Tools
  • 7 New QC Tools
  • Poka Yoke
  • FMEA
  • Lean Six Sigma
  • QC Story Boards
  • Visual Standards

TQM Objectives:

  • First Time Right Manufacturing
  • Reduce Cost of Poor Quality
  • Improving Product Reliability
  • Enhancing Customer Retention & Loyalty


Total Service Management aims at improving services that support the manufacturing operations. This refers to managing the supply chain for an organization, i.e. Suppliers (through purchase planning) and Customers (through back office support).

Lean Tools we use in TSM:

  • Lean Business Processes
  • Lean Inventory Management
  • Lean Spares Management
  • Supply Chain Management
  • Logistics & Distribution Management

TSM Objectives:

  • Efficient Business Processes for reducing Through Put Time
  • Reducing manpower


Total Human Management is the strategic approach to the effective management of people in a company or organization such that they help their business gain a competitive advantage. It is designed to maximize employee performance in service of an employer's strategic objectives. The overall purpose of human resources (HR) is to ensure that the organization is able to achieve success through people.

Lean Tools we use in THM:

  • Lean Organization Architecture
  • Lean KPIs
  • Lean Counselling
  • Team Building
  • Continuous Improvement Programs
  • Health & Safety

ADDVALUE’s Lean execution and sustenance methodology:

  • Preparation of Lean Strategic Roadmap
  • 5S, being the foundation tool, to be applied first, for culture building and ensuring all Lean pillars and tools to sustain
  • Top Management commitment is the key for thwarting the resistances to change
  • Lean Pillars and Tools should converge and align with the organization vision, goals, business excellence model and business philosophy
  • Continual monitoring
  • Creating Lean Themes for employee motivation
  • Recognizing and rewarding Lean efforts
  • ADDVALUE CONSULTING INC (AVCI) integrates and aligns all Lean pillars and tools with organization Business Excellence (BE) model in its Lean Training, Consulting and coaching modules, creating Operational Excellence (OPEX) in each and every aspect of the enterprise.



Understanding, Implementation, Sustenance and Audit of the 5 PILLARS TOTAL LEAN MANAGEMENT - TFM, TPM, TQM, TSM, THM can drive the organizations becoming world class, fit, flexible and competitive in their respective domains and establish leadership in cost, delivery, service and innovation. Business goals are achieved easily through the culture of mutual respect, team work and passion for continual excellence.

Organizations following LEAN KAIZEN principles tend to have better margins, sustained growth and profitability.


For more details about Lean Manufacturing Training & Consulting Email : info@avci-lean.com or Call / Whatsapp : +91 9824009792