Using the Lean Approach for Improving Eco-Efficiency Performance: A Case Study for Plastic Reduction

The project looks at how Lean manufacturing can make production more eco‑efficient and cut plastic waste. It focuses on food processing and uses the A3 problem‑solving tool to find, study, and remove activities that don’t add value but cause extra plastic use. A step‑by‑step diagnostic framework maps material flows, pinpoints the root causes of waste, and applies targeted process changes. The study shows how operational‑efficiency tools can be matched with sustainability goals to sharply reduce single‑use plastic packaging and processing waste. Data from an industrial case study show that plastic use can be cut in half without hurting product quality or production speed. The resulting framework is a scalable model

for manufacturers that want to move toward circular‑economy principles and lower their environmental impact through continuous improvement. This work gives clear guidance for setting up waste‑reduction projects in resource‑intensive manufacturing.

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