The Development History of Lean Tube

Lean tube (also known as wire rod or flexible tube) is a modular assembly system originating from Toyota’s lean production in Japan. Its core advantages lie in flexibility, low cost, and rapid reconfiguration. After four generations of material iterations, it has been widely applied in industries such as manufacturing, warehousing, electronics, automotive, medical, and food.

Origin (1960s-1980s, Japan)

Derived from the Toyota Production System (TPS), its core lies in eliminating waste and pursuing continuous improvement.
Developed by Yazaki Chemicals of Japan, it was initially called “Wire Bar” and used for flexible workstations and material racks in workshops.
During the 1970s and 1980s, North American automakers invested heavily in research and standardization, which was then promoted to the global automotive industry.

Intergenerational evolution of materials (from the 1990s to present)

The first generation (traditional wire rod, 1990s): inner steel tube + outer PVC/PE coating; outer diameter 28mm; load-bearing capacity ≤50kg/m; prone to peeling and deformation; used for light shelves and simple workbenches.

Second generation (composite lean tube, 2000s): high-strength steel tube + improved PE coating; enhanced wear resistance and anti-static properties; load-bearing capacity of 100–150kg/m; used in medium-load production lines, turnover carts, and electronic workstations.

Third generation (stainless steel/aluminum alloy lean tube, 2010s)
Stainless steel: fully stainless steel or with an outer cladding; corrosion-resistant and clean; used in food, pharmaceutical, and dust-free workshops.
Aluminum alloy: lightweight (approximately 1/3 of steel), anodized, high strength; load-bearing capacity of 150–200kg/m; used in high-end electronics, automotive, and automation lines.

The fourth generation (aluminum profile lean tube, 2020s): profile structure + dedicated connectors; higher strength, stronger modularization, and integratable slot positions; used for intelligent factories, automated production lines, and AGV supporting brackets.