Plenty of manufacturers say they’re practicing lean, but without measuring performance, it’s easy to miss signs of trouble. Lean isn’t about slogans—it’s about systems that consistently deliver value to customers with the least amount of waste. If your operations show any of the following warning signs, it may be time to put your lean practices to the test with a self-assessment.

1. Frequent Bottlenecks
Production keeps slowing down, but no one can identify the root cause. This suggests breakdowns in scheduling, process flow, or layout design.

2. Inconsistent Delivery
If on-time delivery performance lags, customers notice. Late shipments can cost you not only money but also long-term relationships.

3. Excess Inventory
Stacks of unused materials, parts, or finished goods signal that flow and demand alignment are off. Inventory is often a symptom of deeper inefficiencies.

4. Limited Employee Involvement
When improvement ideas come only from management, opportunities are being missed. Frontline employees often see waste first.

5. Stalled Improvement Efforts
Maybe you launched a lean program years ago, but energy fizzled out. Without regular evaluation, initiatives fade and bad habits creep back in.

Each of these signs points to waste—whether in time, cost, or talent. A Lean Self-Assessment uncovers the root causes and helps manufacturers build a practical plan to address them. Instead of assuming “we’re lean,” you’ll have data to show exactly where you stand and where to go next.

See if your plant is as lean as you think. Download our Lean Manufacturing Self-Assessment guide and learn how TMEP can help you translate insights into improvement by contact you local solutions consultant HERE.