Lean maturity analysis and lean transformation planning in businesses: Applications in a business operating in the milling machinery sector

Lean Maturity Assessment Analyses (YODA) play a critical role in achieving sustainable growth and gaining competitive advantage within organizations by providing cost advantages, increased efficiency, reduced inventory levels, and enhanced customer satisfaction. These analyses evaluate production processes, workforce efficiency, and overall organizational performance to identify potential improvement areas while fostering a culture of continuous improvement (Kaizen) that forms the foundation of lean manufacturing. In this study, a company that produces its final product through double centrifugal casting followed by machining operations—yet has not previously conducted a lean maturity assessment or transformation plan—was analyzed. The aim was to identify existing deficiencies and determine improvement steps through lean maturity analysis and transformation planning. As a result, productivity losses, workforce inefficiencies, and organizational barriers were identified; strategies and solutions for lean transformation were developed; and a detailed implementation plan was prepared. The research aims to enable the company to make a strong start in its lean transformation journey and serve as a foundation for sustainable efficiency and performance improvements in the future.