Integrating Lean and Green Strategies and Their Effect on Manufacturing Industry Performance: An Empirical Study

This empirical study investigates the integration of Lean and Green manufacturing strategies in 160 Indian manufacturing industries using a structured questionnaire. Reliability analysis confirmed the adequacy of constructs (Cronbach’s alpha > 0.65), and correlation analysis showed significant positive relationships between Lean–Green practices and performance parameters. A z-test identified Kaizen, continuous optimisation, material diversity, and green scheduling as the most influential practices. Hierarchical regression analysis further revealed that Total Productive Maintenance (TPM) acts as a significant moderator, improving the explanatory power of the models. Specifically, the inclusion of TPM increased economic performance by 25.8% and environmental performance by 35%, compared to initial regression results. These findings demonstrate that TPM not only enhances operational efficiency but also strengthens sustainability outcomes. The study provides important contributions to Lean–Green literature by offering empirical evidence from the Indian context and quantifying the moderator role of TPM.Practical implications highlight that Indian firms can tailor lean–green adoption according to their size and resources: small and medium enterprises (SMEs) may begin with cost-effective practices such as 5S, Kaizen, and waste segregation, while larger firms can adopt advanced TPM, energy optimization, and green scheduling. Overall, the research underscores that Lean–Green strategies, when supported by TPM, contribute substantially to both cost savings and environmental sustainability, offering a pathway for long-term sustainable development in the Indian manufacturing sector.