Toyota's success pleases proponents of 'lean'

0 Comments | USA TODAY, May, 2007 | by Del Jones

A cheer went up last week because Toyota sold more cars and trucks than General Motors. The cheer obviously did not erupt from the U.S. auto industry.

Rather, it came from the industry of experts and consultants who sell the no-waste business regimen known as lean manufacturing, a regimen that is popular due almost entirely to Toyota's success.

The publicity about Toyota becoming No.1 will create another burst of energy to lean, even though a survey by management consulting firm Bain shows that just 19% of companies that have tried it are happy with the results, says Mark Gottfredson, Bain's head of performance improvement.

When lean succeeds, it creates efficiency by eliminating seven types of waste, ranging from raw materials to worker time. It...