Lean manufacturing and environmentally responsible practices go hand in hand. Why? Because lean drives plants to optimize for efficiency and relentless reduction of waste. What could be a more perfect match for green manufacturing?
The MPI Group has tracked manufacturers’ use of green practices — and performance on green metrics — since 2010. We’ve found that plants using lean – and/or the related methodology of the Toyota Production System (TPS) – are more likely to use leading green practices and to outperform on green metrics.
Many factors contribute to the success of these lean, green plants, including:
#1. Environment-Friendly Logistics
In 2020, 39% of lean/TPS plants used environment-friendly logistics, compared to just 28% of other plants.
Lean seeks to achieve efficient transportation of materials. For example, in a lean “milk run” strategy, a single inbound or outbound vehicle makes multiple stops in a loop starting and ending at the plant, instead of via multiple vehicles (often with unused capacity) showing up on independent schedules. With fewer vehicles and optimized routes, the milk run can help to reduce emissions.
#2. Recycling/Reuse Programs
MPI data shows that 61% of lean plants have active recycling/reuse programs, vs. just 43% of other plants. Recycling in manufacturing is much more than sorting waste; manufacturers are now sourcing their materials from recycled waste streams and designing their own products to eventually be recycled. Eliminating waste from the manufacturing production process? Lean manufacturers might know a little bit about that!
#3. The Environment of Continuous Improvement
As companies strive to meet their ESG goals, initiatives such as sustainable packaging or tracking PCFs (Product Carbon Footprints) have become increasingly common. But transforming a legacy production system to greener practices is no small undertaking. When companies have a culture of continuous improvement, rigorous performance tracking, and experimentation — e.g., a lean/TPS environment — green initiatives have a platform on which to succeed.
It’s clear to us at MPI that lean and green practices can augment and amplify each other. By streamlining transportation, eliminating waste, and building a strong foundation for continuous improvement, lean manufacturing can help companies achieve their green goals.
It’s not easy being green – but lean can help.
