How Lean Thinking Can Help You Break the Cycle of Firefighting

Manufacturers today face rising costs, labor shortages, and disruptions that can make every day feel like a fire drill. If you’re constantly in reaction mode, or dealing with the same daily problems, it’s time for a new approach. As Beth Aldana, WMEP’s Operational Excellence Services Leader, explains, having a methodology can help manufacturers regain control. And Lean provides practical tools to shift from firefighting to solving problems for good.

Lean Isn’t Extra Work—It’s a Smarter Way to Work

If “Lean” makes you think of binders full of jargon or a massive transformation project, you’re not alone. But as Beth explains, Lean isn’t something you add to your workload—it’s a smarter way to approach it. “Lean is a way of working,” she says. “It’s about helping people see the waste in a process and giving them tools to fix it.” Lean is a practical, flexible approach to improving how work gets done—and making those improvements last. And for those who say, “Lean won’t work here,” or “Our problems are too unique”? Beth calls that a missed opportunity. “Lean concepts work everywhere—from hospitals to coffee shops to every type of manufacturer.”

Tired of Putting Out Fires? Try a Better Approach

Many manufacturers operate in a constant state of reaction—jumping from one issue to the next without a clear plan or lasting results. According to Beth, one of the biggest gaps is the lack of a consistent methodology. “A lot of companies react and apply point solutions, but they miss the mark because they haven’t identified their biggest need—or the right problem to focus on,” she says. That’s where methodology makes a difference. Whether it’s Plan-Do-Check-Act (PDCA) or another simple framework, the goal is to shift from reacting to planning. “It’s not just about fixing what’s broken—it’s about understanding the root cause, testing improvements, validating them with data, and putting systems in place to sustain the gains,” Beth explains.

Start with the Work You’re Already Doing

Many manufacturers assume they need formal training or a big project to begin implementing Lean. But according to Beth, that’s not the case. “Lean can start with a simple conversation,” she says. “Ask your team what frustrates them in the process. You’ll be amazed how much you discover.” Rather than trying to fix everything at once, Lean encourages targeted, manageable improvements. And because those improvements often come from the people doing the work, they’re more likely to stick. “It doesn’t have to be complicated, and you don’t have to boil the ocean. Just start with one step,” Beth emphasizes. “There’s no right or wrong way with Lean. It’s not about being perfect—it’s about being intentional.”

Think Lean Has to Be by the Book? Think Again

Beth explains that a common misconception about Lean is that it’s rigid—something that has to be applied in an exact manner. “I tell manufacturers: you don’t have to do Lean by the book. It will look different at every organization,” she says. “Take the concepts, learn what they mean, and apply them in a way that makes a difference for your business.” The most effective implementations are those rooted in Lean principles and shaped around your people, processes, and culture—not the other way around.

The Long Game: Why Lean Culture Wins Under Pressure

The real power of Lean isn’t just in its tools—it’s in the mindset that improvement is everyone’s job, every day. A culture of continuous improvement helps manufacturers respond to challenges with clarity and confidence, even in high-pressure environments. “When people are empowered to solve problems and eliminate waste, it builds ownership,” Beth says. “And that creates a better workplace with better results.”

WMEP is a nonprofit consulting organization with a simple mission: help Wisconsin manufacturers succeed. Our advisors bring real-world industry experience and deliver practical solutions across three key focus areas: Growth, Operations, and People. Contact us to talk about how Lean Manufacturing principles can help your organization shift from firefighting to problem solving with lasting results.