Management System + Operational Leadership

Take Your Next Performance Leap With Lean 4.0

May 4, 2021

Capture 20% More Improvement with Lean 4.0

Many manufacturers that have been on their lean journeys for some time have hit a plateau. New gains in performance, productivity, and quality are incremental. But operational leaders and executives know there are still significant improvements to be made. They are hungry for the next set of dramatic gains they’ve come to expect from lean.

Lean 4.0 can open the door to your next-generation operational improvements. It provides a way to get at the opportunities hidden in the inner workings of your manufacturing processes.

But there’s more to Lean 4.0 than capturing IIoT data. When it’s done right—through a comprehensive, “prove-and-move” approach focused on three critical areas—Lean 4.0 can generate up to 20% additional improvements in productivity, efficiency, cost per unit, and material and labor variances, leading to significant bottom line gains.

TBM shares its perspective on Lean 4.0 in this insightful new article and explains how a comprehensive, pragmatic approach to next-generation lean ensures the greatest business value.

3 critical tenants of Lean 4.0:

  1. Institutionalizing lean across the organization.
  2. Marrying lean culture with Industry 4.0.
  3. Adopting advanced technologies to understand and address areas of improvement opportunity in business processes.

Complete the form below to download “Leverage Lean 4.0” to learn more about the three pillars of Lean 4.0 and learn the keys to taking a value-driven approach.

TBM Consulting Group

Frequently Asked Questions

What does TBM mean by Lean 4.0 in the context of performance improvement?
Lean 4.0 refers to combining traditional lean principles with digital technologies to expose and eliminate hidden performance losses. The article explains that Lean 4.0 is not about replacing lean with technology, but about using digital tools to improve visibility, decision‑making, and execution discipline. When applied correctly, Lean 4.0 helps organizations uncover improvement opportunities that manual systems and lagging reports often miss.
Why do many performance improvement opportunities remain hidden in manufacturing operations?
Many opportunities remain hidden because variability, waste, and inefficiencies are normalized in daily operations. The article highlights that reliance on averages, delayed reporting, and anecdotal problem‑solving masks true performance gaps. Without real‑time visibility and disciplined management routines, organizations tolerate losses they do not fully see or quantify.
How does Lean 4.0 help organizations unlock these hidden opportunities?
Lean 4.0 helps unlock hidden opportunities by making performance visible in real time and linking insight directly to action. The article emphasizes that digital tools, when paired with lean management systems, allow teams to detect abnormalities sooner and address root causes faster. This combination enables sustained productivity gains, improved reliability, and performance improvement that compounds over time rather than relying on isolated initiatives.

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