Table 3 Lean tool description based on...

Table 3

Lean tool description based on the reviewed studies

Category	Tool	Description	References
Problem Analysis and Resolution
	5 Whys	Technique used to identify the root cause of a problem by asking “why” five times in succession. Helps explore cause-and-effect relationships	Büyüközkan et al. (2015), Saied et al. (2019)
	Affinity Diagram	Tool used to organise ideas and data collected into groups based on natural affinities. Often used during brainstorming sessions	Saha et al. (2014)
	Fishbone Diagram	Also known as Ishikawa or cause-and-effect diagram, used to identify possible causes of a specific problem and organise them visually	Saha et al. (2014)
	Root Cause Analysis	Systematic process used to identify the main cause of a problem. Involves data analysis and application of various problem-solving techniques	Büyüközkan et al. (2015)
	A3	A lean-style report format used to document problem-solving thinking, proposed solutions, and action plans on a single A3-sized sheet of paper	Japa et al. (2023)
	Practical Problem Solving	Structured method for solving practical problems in the workplace using a combination of lean tools and analysis techniques	Al Adawi et al. (2023)
Production Management
	Just-in-Time (JIT)	Production philosophy aimed at reducing waste by producing only what is needed, when it is needed, and in the amount needed	Abidin et al. (2022), Akanmu and Nordin (2022), Cherrafi et al. (2018), Hegedić et al. (2024), Jum'a et al. (2022), Kovács (2020), Rajagopalan (2020), Rasheed et al. (2023), Sahoo (2022), Tanasic (2022)
	Kanban	Production management system that uses visual signals (Kanban cards) to control the flow of materials and ensure Just-in-Time production	Büyüközkan et al. (2015), Carrillo-Corzo et al. (2020), Hegedić et al. (2024), Kovács (2020), Kovilage (2021)
	Cellular Manufacturing	Organisation of production layout into autonomous work cells containing all the resources needed to complete a part or product	Cherrafi et al. (2018), Hegedić et al. (2024), Kovács (2020)
	Continuous Flow	Production technique aimed at reducing downtime and waiting time by ensuring products move continuously through the production process	Akanmu and Nordin (2022), Büyüközkan et al. (2015), Kovilage (2021)
	One-piece Flow	Production of a single piece at a time through the production process, reducing waste and improving quality	Kovács (2020)
	Line Balancing	Technique used to evenly distribute work among workstations in a production line to improve efficiency	Kovács (2020)
	Heijunka	Production levelling technique used to smooth out demand variations and improve production stability	Tanasic et al. (2022)
	Pull Production System (PULL)	Production system where materials are pulled through the production process based on actual demand, rather than pushed based on forecasts	Akanmu and Nordin (2022), Büyüközkan et al. (2015), Kovács (2020), Kovilage (2021)
	Inventory Management	Practices and processes used to control inventory levels, reduce storage costs, and ensure the availability of necessary materials	Hegedić et al. (2024)
Planning and Control
	Value Stream Mapping (VSM)	Visual analysis technique used to map and analyse the flow of materials and information needed to bring a product from concept to customer	Büyüközkan et al. (2015), Chiarini (2014), Choudhary et al. (2019), Japa et al. (2023), Dinis-Carvalho et al. (2023), Estrada-González et al. (2020), Hegedić et al. (2024), Hoque et al. (2020), Kovács (2020), Rasheed et al. (2023), Saied et al. (2019), Silva et al. (2024), Tanasic et al. (2022)
	Suppliers, Inputs, Process, Outputs, Customers (SIPOC)	Process mapping tool that identifies Suppliers, Inputs, Process, Outputs, and Customers of a process	Saha et al. (2014)
	Manufacturing Planning and Control	Production planning and control practices including scheduling, inventory control, and capacity management	Iranmanesh et al. (2019)
	Last Planner System	Work management system used in construction to improve planning and project reliability by involving “last planners” in decision making	Jain et al. (2023)
	Process and Equipment Design	Process and equipment design to improve efficiency, quality, and production safety	Iranmanesh et al. (2019)
	Time Study Analysis	Technique used to measure and analyse the time taken to complete a specific activity or process, to identify improvement opportunities	Saha et al. (2014)
	Visual Control/Management (V.MNG)	Use of visual signals, such as signs, labels, and indicators, to improve communication and control of production processes	García-Alcaraz et al. (2021), Klein et al. (2022), Kovács (2020), Saha et al. (2014)
	Takt-Time Analysis	Calculation of the production pace required to meet customer demand, used to synchronize production processes	Kovács (2020)
	Standardized Work	Definition and documentation of best practices for completing a job efficiently and with high quality	Ciannella and Santos (2022), Japa et al. (2023), Mittal et al. (2016)
	Andon	Visual signalling system used to indicate production status and alert staff to any problems or interruptions	García-Alcaraz et al. (2021)
Measurement and Control
	Key Performance Indicators (KPI)	Key performance indicators used to measure and monitor the effectiveness of business operations and strategies	Hegedić et al. (2024)
	Data Capturing Technique	Methods and tools used to collect and analyse relevant data for process improvement	Mittal et al. (2016)
Quality
	6 Sigma	Continuous improvement methodology that uses statistical techniques to reduce variability and improve process quality	Singh and Rathi (2024)
	Kaizen/Plan-Do-Check-Act (PDCA)	Plan-Do-Check-Act continuous improvement cycle used to implement and evaluate changes in production processes	Büyüközkan et al. (2015), Carrillo-Corzo et al. (2020), Ciannella and Santos (2022), Hegedić et al. (2024), Jum'a et al. (2022), Klein et al. (2022), Kovilage (2021), Mittal et al. (2016), Sahoo (2022), Silva et al. (2024), Tanasic et al. (2022)
	Statistical Process Control	Use of statistical techniques to monitor and control production processes, to improve quality and reduce variability	Akanmu and Nordin (2022)
	Poka-Yoke	Mistake-proofing devices or procedures designed to prevent or detect errors before they cause product defects	Büyüközkan et al. (2015), García-Alcaraz et al. (2021), Japa et al. (2023), Tanasic et al. (2022)
	Total Quality Management (TQM)	Management approach aimed at continuously improving product and process quality by involving all levels of the organisation	Jain et al. (2023), Sahoo (2022)
	Overall Equipment Effectiveness (OEE)	Measure of the overall performance of a plant or machine, considering availability, performance, and quality	Zehra et al. (2024)
	Jidoka	Lean principle that enables machines and operators to detect quality problems and immediately stop production to prevent defects	Tanasic et al. (2022)
	Defect per Hundred Unit (DHU)	Quality measure indicating the number of defects per hundred units produced, used to monitor and improve product quality	Hoque et al. (2020)
	Process Optimisation	Continuous improvement activities aimed at optimising the efficiency, quality, and productivity of production processes	Rasheed et al. (2023)
	Technical Emphasis	Focus on technical and engineering aspects of process improvement, including process analysis and design	Sahoo (2022)
Maintenance
	Total Productive Maintenance (TPM)	Maintenance strategy aimed at improving equipment productivity by involving all staff in preventive and corrective maintenance	Abidin et al. (2022), Akanmu and Nordin (2022), Chen et al. (2019), Chiarini (2014), Ciannella and Santos (2022), Hegedić et al. (2024), Sahoo (2022), Silva et al. (2024)
	Preventive Maintenance	Regularly scheduled maintenance to prevent failures and extend equipment life	Kovilage (2021)
	Set-up Time Reduction	Techniques used to reduce the time needed to change or set up equipment, improving production efficiency	Akanmu and Nordin (2022), Cherrafi et al. (2018)
	Single Minute Exchange of Die (SMED)	Methodology to drastically reduce setup times in production operations	Büyüközkan et al. (2015), Carrillo-Corzo et al. (2020), Chiarini (2014), Japa et al. (2023), Hegedić et al. (2024), Hoque et al. (2020), Saha et al. (2014)
Design and Ergonomics
	Product Design	Process of designing new products or improving existing ones to meet customer needs and improve manufacturability	Iranmanesh et al. (2019)
	Workplace Ergonomics (5S)	Study and application of ergonomic principles to design workplaces that improve worker safety, comfort, and productivity	Büyüközkan et al. (2015), Carrillo-Corzo et al. (2020), Chiarini (2014), Ciannella and Santos (2022), Dube and Gupta (2023), Hegedić et al. (2024), Hoque et al. (2020), Jain et al. (2023), Kovács (2020), Rajagopalan (2020), Rasheed et al. (2023), Tanasic et al. (2022)
Engagement and Relationship
	Management and Leadership Support	Active involvement of business leaders in supporting and promoting continuous improvement initiatives and lean culture	Klein et al. (2022)
	Employee Involvement	Active involvement of employees at all levels in identifying and implementing process improvements	Akanmu and Nordin (2022), Kovilage (2021)
	Empowerment and Collaboration	Strategy that encourages employee empowerment and collaboration to improve processes and solve problems	Klein et al. (2022)
	Gemba	Japanese term meaning “the real place”, used to describe the importance of observing and understanding production processes directly on the shop floor	Tanasic et al. (2022)
	Customer Relationship Management	Systems and strategies used to manage customer interactions and relationships, improving customer satisfaction and loyalty	Iranmanesh et al. (2019)
	Supplier Relationship Management	Management of relationships with suppliers to optimise supply chain performance and improve quality and efficiency	Iranmanesh et al. (2019)

Category	Tool	Description	References
Problem Analysis and Resolution
	5 Whys	Technique used to identify the root cause of a problem by asking “why” five times in succession. Helps explore cause-and-effect relationships	Büyüközkan et al. (2015), Saied et al. (2019)
	Affinity Diagram	Tool used to organise ideas and data collected into groups based on natural affinities. Often used during brainstorming sessions	Saha et al. (2014)
	Fishbone Diagram	Also known as Ishikawa or cause-and-effect diagram, used to identify possible causes of a specific problem and organise them visually	Saha et al. (2014)
	Root Cause Analysis	Systematic process used to identify the main cause of a problem. Involves data analysis and application of various problem-solving techniques	Büyüközkan et al. (2015)
	A3	A lean-style report format used to document problem-solving thinking, proposed solutions, and action plans on a single A3-sized sheet of paper	Japa et al. (2023)
	Practical Problem Solving	Structured method for solving practical problems in the workplace using a combination of lean tools and analysis techniques	Al Adawi et al. (2023)
Production Management
	Just-in-Time (JIT)	Production philosophy aimed at reducing waste by producing only what is needed, when it is needed, and in the amount needed	Abidin et al. (2022), Akanmu and Nordin (2022), Cherrafi et al. (2018), Hegedić et al. (2024), Jum'a et al. (2022), Kovács (2020), Rajagopalan (2020), Rasheed et al. (2023), Sahoo (2022), Tanasic (2022)
	Kanban	Production management system that uses visual signals (Kanban cards) to control the flow of materials and ensure Just-in-Time production	Büyüközkan et al. (2015), Carrillo-Corzo et al. (2020), Hegedić et al. (2024), Kovács (2020), Kovilage (2021)
	Cellular Manufacturing	Organisation of production layout into autonomous work cells containing all the resources needed to complete a part or product	Cherrafi et al. (2018), Hegedić et al. (2024), Kovács (2020)
	Continuous Flow	Production technique aimed at reducing downtime and waiting time by ensuring products move continuously through the production process	Akanmu and Nordin (2022), Büyüközkan et al. (2015), Kovilage (2021)
	One-piece Flow	Production of a single piece at a time through the production process, reducing waste and improving quality	Kovács (2020)
	Line Balancing	Technique used to evenly distribute work among workstations in a production line to improve efficiency	Kovács (2020)
	Heijunka	Production levelling technique used to smooth out demand variations and improve production stability	Tanasic et al. (2022)
	Pull Production System (PULL)	Production system where materials are pulled through the production process based on actual demand, rather than pushed based on forecasts	Akanmu and Nordin (2022), Büyüközkan et al. (2015), Kovács (2020), Kovilage (2021)
	Inventory Management	Practices and processes used to control inventory levels, reduce storage costs, and ensure the availability of necessary materials	Hegedić et al. (2024)
Planning and Control
	Value Stream Mapping (VSM)	Visual analysis technique used to map and analyse the flow of materials and information needed to bring a product from concept to customer	Büyüközkan et al. (2015), Chiarini (2014), Choudhary et al. (2019), Japa et al. (2023), Dinis-Carvalho et al. (2023), Estrada-González et al. (2020), Hegedić et al. (2024), Hoque et al. (2020), Kovács (2020), Rasheed et al. (2023), Saied et al. (2019), Silva et al. (2024), Tanasic et al. (2022)
	Suppliers, Inputs, Process, Outputs, Customers (SIPOC)	Process mapping tool that identifies Suppliers, Inputs, Process, Outputs, and Customers of a process	Saha et al. (2014)
	Manufacturing Planning and Control	Production planning and control practices including scheduling, inventory control, and capacity management	Iranmanesh et al. (2019)
	Last Planner System	Work management system used in construction to improve planning and project reliability by involving “last planners” in decision making	Jain et al. (2023)
	Process and Equipment Design	Process and equipment design to improve efficiency, quality, and production safety	Iranmanesh et al. (2019)
	Time Study Analysis	Technique used to measure and analyse the time taken to complete a specific activity or process, to identify improvement opportunities	Saha et al. (2014)
	Visual Control/Management (V.MNG)	Use of visual signals, such as signs, labels, and indicators, to improve communication and control of production processes	García-Alcaraz et al. (2021), Klein et al. (2022), Kovács (2020), Saha et al. (2014)
	Takt-Time Analysis	Calculation of the production pace required to meet customer demand, used to synchronize production processes	Kovács (2020)
	Standardized Work	Definition and documentation of best practices for completing a job efficiently and with high quality	Ciannella and Santos (2022), Japa et al. (2023), Mittal et al. (2016)
	Andon	Visual signalling system used to indicate production status and alert staff to any problems or interruptions	García-Alcaraz et al. (2021)
Measurement and Control
	Key Performance Indicators (KPI)	Key performance indicators used to measure and monitor the effectiveness of business operations and strategies	Hegedić et al. (2024)
	Data Capturing Technique	Methods and tools used to collect and analyse relevant data for process improvement	Mittal et al. (2016)
Quality
	6 Sigma	Continuous improvement methodology that uses statistical techniques to reduce variability and improve process quality	Singh and Rathi (2024)
	Kaizen/Plan-Do-Check-Act (PDCA)	Plan-Do-Check-Act continuous improvement cycle used to implement and evaluate changes in production processes	Büyüközkan et al. (2015), Carrillo-Corzo et al. (2020), Ciannella and Santos (2022), Hegedić et al. (2024), Jum'a et al. (2022), Klein et al. (2022), Kovilage (2021), Mittal et al. (2016), Sahoo (2022), Silva et al. (2024), Tanasic et al. (2022)
	Statistical Process Control	Use of statistical techniques to monitor and control production processes, to improve quality and reduce variability	Akanmu and Nordin (2022)
	Poka-Yoke	Mistake-proofing devices or procedures designed to prevent or detect errors before they cause product defects	Büyüközkan et al. (2015), García-Alcaraz et al. (2021), Japa et al. (2023), Tanasic et al. (2022)
	Total Quality Management (TQM)	Management approach aimed at continuously improving product and process quality by involving all levels of the organisation	Jain et al. (2023), Sahoo (2022)
	Overall Equipment Effectiveness (OEE)	Measure of the overall performance of a plant or machine, considering availability, performance, and quality	Zehra et al. (2024)
	Jidoka	Lean principle that enables machines and operators to detect quality problems and immediately stop production to prevent defects	Tanasic et al. (2022)
	Defect per Hundred Unit (DHU)	Quality measure indicating the number of defects per hundred units produced, used to monitor and improve product quality	Hoque et al. (2020)
	Process Optimisation	Continuous improvement activities aimed at optimising the efficiency, quality, and productivity of production processes	Rasheed et al. (2023)
	Technical Emphasis	Focus on technical and engineering aspects of process improvement, including process analysis and design	Sahoo (2022)
Maintenance
	Total Productive Maintenance (TPM)	Maintenance strategy aimed at improving equipment productivity by involving all staff in preventive and corrective maintenance	Abidin et al. (2022), Akanmu and Nordin (2022), Chen et al. (2019), Chiarini (2014), Ciannella and Santos (2022), Hegedić et al. (2024), Sahoo (2022), Silva et al. (2024)
	Preventive Maintenance	Regularly scheduled maintenance to prevent failures and extend equipment life	Kovilage (2021)
	Set-up Time Reduction	Techniques used to reduce the time needed to change or set up equipment, improving production efficiency	Akanmu and Nordin (2022), Cherrafi et al. (2018)
	Single Minute Exchange of Die (SMED)	Methodology to drastically reduce setup times in production operations	Büyüközkan et al. (2015), Carrillo-Corzo et al. (2020), Chiarini (2014), Japa et al. (2023), Hegedić et al. (2024), Hoque et al. (2020), Saha et al. (2014)
Design and Ergonomics
	Product Design	Process of designing new products or improving existing ones to meet customer needs and improve manufacturability	Iranmanesh et al. (2019)
	Workplace Ergonomics (5S)	Study and application of ergonomic principles to design workplaces that improve worker safety, comfort, and productivity	Büyüközkan et al. (2015), Carrillo-Corzo et al. (2020), Chiarini (2014), Ciannella and Santos (2022), Dube and Gupta (2023), Hegedić et al. (2024), Hoque et al. (2020), Jain et al. (2023), Kovács (2020), Rajagopalan (2020), Rasheed et al. (2023), Tanasic et al. (2022)
Engagement and Relationship
	Management and Leadership Support	Active involvement of business leaders in supporting and promoting continuous improvement initiatives and lean culture	Klein et al. (2022)
	Employee Involvement	Active involvement of employees at all levels in identifying and implementing process improvements	Akanmu and Nordin (2022), Kovilage (2021)
	Empowerment and Collaboration	Strategy that encourages employee empowerment and collaboration to improve processes and solve problems	Klein et al. (2022)
	Gemba	Japanese term meaning “the real place”, used to describe the importance of observing and understanding production processes directly on the shop floor	Tanasic et al. (2022)
	Customer Relationship Management	Systems and strategies used to manage customer interactions and relationships, improving customer satisfaction and loyalty	Iranmanesh et al. (2019)
	Supplier Relationship Management	Management of relationships with suppliers to optimise supply chain performance and improve quality and efficiency	Iranmanesh et al. (2019)

Source(s): Authors’ own work

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