An integrated lean and green approach for improving sustainability performance: a case study of a packaging manufacturing SME in the U.K.

TLDR

Competitive landscape, informed consumers, and stringent regulations have pushed many manufacturing SMEs to pursue operational efficiency and sustainability, yet many adopt lean without a strategic vision, leading to scattered implementation and a lack of empirical evidence on the synergy between lean and green paradigms. The study aims to integrate lean and green approaches by applying a novel Green Integrated Value Stream Mapping (GIVSM) tool in a UK packaging‑manufacturing SME. The authors employ a systematic methodology that introduces the GIVSM tool and a continuous‑improvement framework incorporating sustainable procurement to align lean and green initiatives. The GIVSM demonstrates synergistic gains in operational efficiency and environmental performance, provides a practical reference for similar projects, and identifies opportunities to extend the integrated lean‑green approach to other industry sectors.

Abstract

Competitive landscape, informed consumers and stringent regulations have forced many manufacturing small- and medium-sized enterprises (SMEs) to focus on operational efficiency along with sustainability issues in recent years. While many manufacturing organisations have been taking lean initiatives for the past few years for operational excellence, an impulsive rush to adopt lean without a strategic deployment vision has led to scattered implementation of lean tools and projects without desired success. Many researchers and practitioners prescribe value stream mapping as a foundation for lean transformation initiatives; however, little empirical work is available on the symbiosis of lean and green paradigms to reap maximum benefits. This research, through a systematic methodology and a novel tool called Green Integrated Value Stream Mapping (GIVSM), integrates both paradigms in a case study on a U.K. packaging-manufacturing SME. Applying the GIVSM demonstrates that simultaneous deployment of lean and green paradigms have synergistic effect for improving both operational efficiency and environmental performance. In addition, continuous improvement framework with sustainable procurement is proposed to overcome the lean-green misalignments. This study also provides a guiding reference for practitioners to undertake similar improvement projects and identifies opportunities to expand this academic research on integrated lean-green approach into other industry sectors.