Integration of lean-green manufacturing and simulation modeling for sustainable production efficiency improvement
Keywords:
Lean-green manufacturing, Sustainable production, Simulation modeling, Industrial engineering, Energy efficiencyAbstract
Manufacturing industries are increasingly required to improve production efficiency while reducing environmental impacts. However, many production systems still experience long lead times, high energy consumption, and excessive material waste. This study aims to develop an integrated Lean–Green Manufacturing framework supported by simulation modeling to improve both operational performance and environmental sustainability. The research was conducted by first identifying production inefficiencies using Value Stream Mapping and lean assessment tools. Environmental indicators, including energy consumption and material waste, were then incorporated into the improvement analysis. A discrete-event simulation model was developed using Arena software to represent the current production system and to evaluate alternative Lean–Green improvement scenarios before real implementation. The simulation results show that the integrated Lean–Green scenario provides significant improvements compared to the existing system. Total production lead time was reduced by 23.2%, cycle time decreased by 20.2%, and production throughput increased by 21.2%. In addition, energy consumption was reduced by 21.0%, while material waste decreased by 27.9%, indicating a substantial improvement in environmental performance. These findings demonstrate that integrating Lean and Green approaches, validated through simulation modeling, can effectively enhance production efficiency while supporting sustainable manufacturing objectives. The proposed framework also serves as a practical decision-support tool for industries seeking to implement sustainability-driven improvements with minimal operational risk.
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