Performance enhancement of solid waste processing through lean-based simulation modeling

Purpose This paper introduces a framework for analyzing and optimizing the operations of a municipal solid waste processing facility, grounded in lean thinking and theory, to maximize operational efficiency. The study addresses the gaps in previous research by proposing a comprehensive approach that handles the variability in operation of the refuse-derived fuel (RDF) production unit in the solid waste processing stream, offering promising solutions for waste management professionals and municipal decision-makers. Design/methodology/approach The research methodology used in this study is design science research (DSR). The outcome is a framework that integrates value stream mapping (VSM) with discrete event simulation (DES) modeling to examine the effects of various lean interventions on the overall RDF process. The framework was applied to a state-of-the-art municipal solid waste processing facility where data were collected from operations and maintenance logs, interactions at the facility and interviews with industry experts and stakeholders. Findings Simulation results demonstrate that the combined lean interventions – preventive maintenance, repair-time reduction through data-driven inventory management and optimized dual-line operation – can reduce equipment downtime between 36% and 87% and increase overall throughput by approximately 10%–23% compared with the base case. These results confirm that the proposed framework can substantially enhance processing performance and operational resilience. Research limitations/implications The study contributes to methodological development by providing a replicable framework that integrates DES with lean thinking to improve processes in solid waste facilities. Future research may extend this framework to include other units and facilities. Practical implications The study presents a practical framework that can be adopted for decision-making in operations and maintenance of processing facilities. Originality/value This paper introduces a unique framework with lean interventions to enhance operational flow in solid waste processing. It establishes a foundation for future research and ongoing improvements in the operations and maintenance of waste management facilities.