Lean Manufacturing Principles: 7 Ways to Eliminate Waste

Biltay Academy December 20, 2025

Born from the Toyota Production System, the lean manufacturing philosophy is now applied across every industry worldwide. The basic principle is simple: any activity that does not add value to the customer is waste and must be eliminated.

7 Types of Waste

  1. Overproduction: Producing more than needed
  2. Waiting: Unnecessary waiting times between processes
  3. Transportation: Unnecessary material movements
  4. Over-processing: Extra processing the customer did not request
  5. Inventory: Excess raw materials, WIP, or finished goods
  6. Motion: Unnecessary physical movements by operators
  7. Defects/Scrap: Defective products and rework

Lean Manufacturing with Digital Tools

BilTAY supports lean manufacturing consulting with digital tools:

  • ProCOST MES to detect waste in real-time
  • Kokpit BI to monitor OEE and efficiency KPIs
  • Scienta ERP to optimize production planning
  • Process Analysis to identify bottlenecks

BilTAY Consulting Approach

The BilTAY Consulting team goes down to the factory floor to analyze your current state. Using lean tools such as Value Stream Mapping, 5S, Kaizen, and SMED, they improve your processes.

Start your lean transformation today.