Understand what their customers value. Methods for achieving this include getting direct feedback, requesting product reviews, initiating surveys and conducting in-depth market research, all complemented with sales and returns data analysis. This customer-centric approach ensures that every process improvement aligns with customer expectations. Lean manufacturers must prepare their workforce for adapting to new ways of working amid the ever-improving environment that lies at the heart of a lean operation. By using a pull system, manufacturers align their manufacturing output with real-time customer demand for goods. With careful planning and demand analytics, however, manufacturers can minimize their risks and effectively meet demand.

Based on my experience, quality is a basic requirement and can’t be compromised in any way and cutting costs essential to remain competitive in the market. I believe that both can be achieved by having a strong purchasing team for raw materials and an innovative operations team to improve in efficiency and reduce loss during the production process.

It’s possible to cut costs while keeping quality high in lean manufacturing. The key is to remove waste without removing value. Start by analyzing each step of the production process to find where time, materials, or effort are being wasted. Improving workflow, reducing downtime, and using resources more efficiently can lower costs. At the same time, focus on quality checks during production, not just at the end. This helps catch problems early and avoid rework. Training workers and encouraging teamwork also leads to better results with fewer errors. With the right mindset and systems, lean manufacturing can save money and improve quality at the same time.

From my experience in R&D within paint manufacturing, balancing cost and quality comes down to smart raw material substitution, real-time quality checks, and continuous process improvement. Collaborating closely across teams, from procurement to production, also helps ensure we hit both performance and cost targets without compromising standards. It's about working smarter, not just cheaper.

Balancing cost and quality in lean manufacturing hinges on embedding continuous improvement (Kaizen), leveraging JIT to minimize waste, and empowering skilled employees to uphold standards. Standardized work, root cause analysis (like 5 Whys), and poka-yoke (error-proofing) further reduce defects and rework costs. Cross-functional teams that own quality help spot savings without compromising output. Ultimately, cost and quality aren’t trade-offs—they’re outcomes of a disciplined, waste-free process.