What I Learned About Lean Visual Signals from the Waffle House

In Lean methodology, a kanban chart – from the Japanese word meaning “signboard” – is a simple yet powerful visual signal. In our Lean and Six Sigma training programs, we emphasize that visual data is one of the most effective ways to manage performance in real time.

Lean Visual Signals ensure that operators spend their time adding value to a product or service rather than performing non-value-added tasks like searching for schedules, filling out reports, or leaving their station to gather materials.

When implemented correctly, Lean Visual Signals (such as kanban boards, TAKT time charts, or pull systems) communicate performance instantly. They show operators “what’s next” without pausing for investigation or manual checks. While some companies overinvest in costly digital systems, others find surprisingly simple, effective solutions.

One of the best examples I’ve seen comes from an unexpected place: the Waffle House.

How Does the Cook Remember All Those Orders?

Sitting in a Waffle House one morning, I was amazed by the cook’s ability to juggle multiple customer orders as they were called out. At first, I assumed it was pure memorization. But after watching closely, I noticed something remarkable.

Each plate acted as a kanban board, and condiments served as visual signals. The cook placed ketchup, mustard, or jelly in specific spots on the plates – not randomly, but in a consistent, repeatable way.

This system was brilliant in its simplicity: the placement of condiments represented the details of each order. Without looking at a paper ticket or digital screen, the cook could instantly know what to prepare next.

That’s Lean Visual Management at its finest – simple, low-cost, and incredibly effective.

Simplify, Innovate, Automate: The Lean Hierarchy in Action

In Lean and Six Sigma courses, we teach the hierarchy of improvements:

1. Simplify – Streamline the process using available tools.
2. Innovate – Redesign the process when simplification isn’t enough.
3. Automate – Apply technology as the final step, not the first.

Too often, companies skip directly to automation, implementing expensive ERP or MRP systems to fix already broken processes. The result? Even more complexity and longer lead times.

Waffle House didn’t fall into this trap. Instead, they simplified. They asked: “How can we make the order process visual with what we already have?” The answer was right in front of them – condiments.

It’s a real-world example of Lean thinking: reduce waste, communicate visually, and empower people to focus on value-added work.

Now I Challenge You to Look for Lean Visual Signals…

Lean tools aren’t limited to factories or offices. They’re everywhere if you know how to spot them.

The next time you visit a Waffle House (or any busy restaurant), observe how orders are communicated. Do you notice visual management techniques in action? Plates, condiments, or even where food is placed on a counter may serve as kanban-like signals.

Come back to this article and share in the comments how you saw Lean Visual Signals used. It’s a great way to sharpen your eye for continuous improvement opportunities in daily life.

Related SSDSI Posts

• What Einstein Taught Me About Lean Six Sigma
• Lean and Six Sigma Deployment Program
• The Lean Zone® Sub-Assembly Simulation
• Example of a Lean Pull Process at McDonalds
• How to Conduct a Simple Hypothesis Test in Six Sigma