To meet evolving customer expectations, companies need to take into consideration most challenging requirements. To help designers meet these increased needs, various methodologies, known as “Design for X (DfX)”, have been created. Nowadays, companies rely on a conventional view of Lean application during the use phase to integrate new requirements: let the system produce, detect wastes, then apply Lean tools to remedy them. However, this solution confront several limitations and constraints such as the initial design of the existing system, time and cost of implementing new Lean tools and resistance to change, etc. This implies a change of mindset by proactively integrate Lean requirements from the design phase. This paper aims to support designers in improving the overall performance of production systems by designing Leanless (Minimal Lean application required) sustainable, adaptable systems with minimal waste and human-centered considerations. For this purpose, we have analyzed Lean principles and tools in an Industry 5.0 context in the aim to extract a set of Lean requirements and parameters in line with Industry 5.0 principles. In addition, we have conducted a literature review of 34 DfX methodologies and classified them into six categories: Production, maintenance, quality, sustainability, human-centricity and Resilience. For each category, we have identified the Lean requirements and parameters that meet its objectives. To assess Lean requirements and select the appropriate Lean tools to be integrated from the design phase, we recommend the use of Multi-Criteria Decision Making (MCDM) methods. In addition, this study proposes to take advantage of inventive design to resolve potential contradictions between Lean requirement parameters and technical parameters. This study can serve as a guide for designers, assisting them in considering various requirements that can enhance the performance of the system being designed.
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