How to Start a Lean Project in 5 Practical Steps

Lean thinking isn’t just a buzzword — it’s a powerful, structured approach to improving performance by eliminating waste, reducing delays, and focusing on what truly adds value.

But many manufacturers, especially small to mid-sized ones, ask:“Where do we even begin?”

At FactoryLean AI, we guide manufacturers to start Lean projects quickly, affordably, and effectively. Whether you’re tackling downtime, poor flow, or inefficiency, here’s a 5-step roadmap to get your Lean project off the ground.

✅ Step 1: Identify the Right Problem

Not every issue needs a full Lean project. Focus on a problem that’s urgent, chronic, and causes pain — such as:

• Long setup/changeover times

• High rework or defect rates

• Bottlenecks slowing production

• Excessive inventory or motion

• A frustrating process your team complains about

Tip: Talk to operators — they know where the pain points are.

📊 Step 2: Measure the Current State

Before you fix anything, you need to know where you stand.

• Use tools like Value Stream Mapping (VSM) to visualize flow

• Track downtime, cycle time, WIP, and scrap

• Use Excel or Power BI to collect and analyze data (we can help)

The goal here is to establish a baseline so you can measure improvement.

🔍 Step 3: Analyze the Root Causes

Don’t just treat the symptoms — dig deep.

Use Lean tools like:

• 5 Whys

• Cause & Effect (Fishbone) Diagram

• Pareto Analysis

You want to uncover what’s really causing the problem, not just what’s visible.

🚀 Step 4: Improve with Lean Tools

Once the root cause is clear, apply the right solution. Depending on the issue, this may involve:

• 5S (workplace organization)

• SMED (single-minute exchange of die / setup reduction)

• Standard Work

• Error-Proofing (Poka-Yoke)

• Flow balancing or Kanban

Always involve the frontline team in brainstorming and testing solutions.

📈 Step 5: Sustain with Visuals & Habits

The hardest part is keeping the gains.

• Create visual management boards

• Set KPIs and dashboards to monitor results

• Train team members and supervisors

• Celebrate early wins to keep motivation high

Bonus Tip: We offer Lean Training & Coaching to help your team embed these changes.

Start Small. Improve Fast.

You don’t need to redesign your whole factory. Start with one line, one team, one process — and build from there.

At FactoryLean AI, we help manufacturers combine Lean, Six Sigma, and Smart Tools to create sustainable improvements — without massive cost or disruption.

📞 Book a free discovery call today📧 info@factorylean.ai | 🌐 www.factorylean.ai