Implementing Lean and Green Strategies for Sustainable Efficiency in the Indian Steel Sector

This research presents a comprehensive case study on the integration of Lean and Green manufacturing strategies at a small scale ABC Alloys Ltd non-ferrous metal processing enterprise. The company faced multiple operational and environmental challenges, such as high levels of production waste, excessive energy consumption, extended lead times, and inadequate compliance with environmental regulations. To address these issues, a structured transformation initiative was undertaken that combined Lean tools namely 5S, Kaizen, Single-Minute Exchange of Dies (SMED), and Value Stream Mapping (VSM) with Green practices like wastewater recycling, LED lighting retrofitting, and the implementation of noise reduction systems. This integrated Lean-Green approach led to notable improvements, including reduced scrap generation, optimized energy and water usage, shorter production lead times, and increased employee engagement through participatory methods. The case demonstrates that even resource constrained Small and Medium Enterprises (SMEs) can successfully adopt Lean-Green strategies to achieve operational efficiency, environmental sustainability, and long term cost savings. The findings underline the viability of a systematic and phased implementation model, offering a scalable roadmap for similar manufacturing units across India.