Using the Lean-Based Safety Leadership Framework to Improve Operational Efficiency and Reduce Occupational Risk: Evidence from a Case Study

Abstract This study explores the integration of Lean methodologies with occupational safety enhancement in an industrial context. Conducted in a renown Rope factory, the research utilized an Action Research methodology guided by a novel Lean-Based Safety Leadership Framework. Through the implementation of Lean tools such as SMED, 5S, Poka-Yoke, and Visual Management, it is possibe to improve both operational efficiency and occupational safety. A Safety Efficiency Value Stream Mapping (SEVSM) approach was employed to diagnose risk points and inefficiencies within one of the factory’s sectors. The intervention led to a significant reduction in operational risk and improvements in productivity, validating the framework’s effectiveness as a dual-propose tool for safety and efficiency.