By Chris Cookson
Can the lean supply chain get too lean? That’s a hot topic now that Toyota is suffering safety and quality woes possibly related to its supply chain. While the lean manufacturing pioneer grapples with the fallout and recovery from “unintended acceleration” and other issues, high-tech manufacturers would do well to view the troubles at Toyota as a cautionary tale in lean supply chain practices. Regardless of the final verdict on Toyota, the supply chain can, indeed, get too lean. As a veteran of several lean implementations in the high-tech industry, I’ve got a few suggestions for staying on the right side of the lean line.
Don’t dismiss Toyota. People who say that Toyota has messed up because of lean are not clear about Toyota’s history or the real root cause of their problems. Toyota has a great supply chain as well as the original and best, long-term implementation of lean manufacturing. In fact, the Toyota Production System that the company started...



