Todd Kovi

Lean manufacturing is all about reducing waste and increasing efficiency. Manufacturers have been implementing lean practices for decades and have stood the test of time. Now, with technological advancements, lean methodologies can be more transformative than ever before. “Integrating automation into lean manufacturing is a powerful strategy. Unlike traditional automation, which often aims to increase production capacity without considering real needs, lean automation focuses on the smart and selective application of technologies to meet specific continuous improvement goals and eliminate inefficiencies,” the Kaizen Institute said. “Digital transformation provides an unprecedented opportunity for implementing lean,” it continued. “When applied within lean, tools like the Internet of Things (IoT), artificial intelligence (AI), and data analytics can revolutionize how organizations detect and eliminate waste.” What is Lean Manufacturing? In “The Machine That Changed The World,” published in 1990, lean production is hailed as “Toyota’s secret weapon in the global car wars.” The Toyota Production System was developed following World War II from “a series of simple innovations … to provide both continuity in process flow and a wide variety in product offerings,” according to the Lean Enterprise Institute. In “Lean Thinking,” a 1996 follow-up to “The Machine That Changed The World,” authors James…

This post is written in partnership with Reuters Events: Supply Chain. Reuters Events connects the world’s most senior supply chain leaders through conferences, research, and digital content. Learn more: events.reutersevents.com/supply-chain/usa   When decisions cannot keep pace with change There is a moment most planning leaders recognise right now: A tariff announcement lands. A carrier pulls capacity. Demand accelerates faster than the forecast adjusts. The decision window compresses, and by the time there is confidence in the data, the cost of delay is already building. These pressures across supply chains are not new. What has changed is the speed at which conditions move underneath a decision, often faster than organisations are set up to respond. Customer expectations do not flex when supply does not. The cost of a wrong call, whether inventory in the wrong market, capacity committed too early, or service levels slipping before anyone flags them, compounds quickly. Most organisations have responded by investing. Better tools. More data. AI pilots. Network reviews. The core problem persists: decisions are still being made without full confidence. Planning and execution do not align when conditions change. In many cases, the issue is not disruption itself. It is how long organisations take to…