Development and sustainability challenges in the maquiladora industry: A lean perspective

• VSM is a precursor of TPM and JIT in the manufacturing industry. • JIT and TPM encourage the implementation of social, environmental, and economic sustainability. Economic sustainability is accounted for by TPM and JIT at 41.9 %. • VSM, JIT, and TPM are obtained within five years of implementation. • 5S is reached at 100 % at 14 years of age and social sustainability at 15 years. The Mexican maquiladora industry faces high pressure to achieve sustainability while maintaining operational efficiency. This study investigates how key Lean Manufacturing (LM) tools—5S, Value Stream Mapping (VSM), Total Productive Maintenance (TPM), and Just-in-Time (JIT)—contribute to economic, environmental, and social sustainability in this context. To analyze these relationships, a structural equation model (SEM) was developed based on 411 validated survey responses collected from mid- and senior-level personnel working in operations, production, quality, and maintenance areas. Additionally, system dynamics (SD) modeling was applied to simulate the long-term effects of LM implementation. The results show that VSM and JIT strongly influence economic sustainability, whereas TPM plays a key role in promoting environmental and social sustainability. The findings also indicate that social sustainability takes longer to consolidate, up to 15 years, while LM tools are implemented more rapidly. By integrating SEM and SD, this study offers a dynamic perspective on sustainability outcomes and provides practical guidance for managers and policymakers to align LM strategies with their long-term sustainability goals.