From Lean Waste to Measurable Sustainability: Data-Driven Optimization in Smart Manufacturing

Ifeyinwa Faith Ogbodo¹, Charles Chikwendu Okpala², Onyekachi Marcel Egwuagu³

¹ Senior Lecturer, Industrial/Production Engineering Department, Nnamdi Azikiwe University, Awka, Anambra State, Nigeria.

² Professor, Industrial/Production Engineering Department, Nnamdi Azikiwe University, Awka, Anambra State, Nigeria.

³ Assoc. Professor, Department of Mechatronics Engineering, Enugu State University of Science and Technology, Nigeria. 

Abstract

Manufacturing firms are increasingly required to demonstrate measurable sustainability performance alongside traditional productivity objectives. Although lean manufacturing has long emphasized waste reduction, its sustainability benefits are often assumed rather than empirically verified. This study proposes a data-driven and multidisciplinary framework that systematically converts lean waste reduction into quantifiable sustainability outcomes within smart manufacturing environments. The framework integrates lean waste operationalization, Industrial Internet of Things (IIoT)-enabled data acquisition, machine learning-based multi-objective optimization, and unit-level sustainability assessment. Using high-frequency operational and energy data from an industrial smart manufacturing case study, the approach enables direct attribution of environmental impacts to specific process behaviors. Empirical results showed 18.7% statistically significant reductions in energy intensity, 22.4% material scrap, and 16.1% carbon emissions per unit, achieved without sacrificing throughput and with a modest productivity gain. Through the grounding of sustainability improvements in real-time operational data and validated optimization outcomes, this study moves beyond conceptual alignment between lean and sustainability and also provides verifiable evidence of their integration. The proposed framework is replicable, scalable, and theoretically grounded, as it offers a robust foundation for future research at the intersection of lean manufacturing, smart manufacturing, and sustainable production.    

Keywords: Lean manufacturing, Smart manufacturing, Data-driven optimization, Industrial internet of things, Sustainable manufacturing, Energy efficiency, Carbon emissions  

References

1. Ajaefobi, J.O. and Okpala, C.C. (2026) ‘Optimization of smart manufacturing systems through renewable energy integration and sustainable material utilization’, International Journal of Engineering Inventions, 15(2), pp. 18-32.  https://www.ijeijournal.com/papers/Vol15-Issue2/15021832.pdf
2. Aguh, P.S., Udu, C.E., Chukwumuanya, E.O., et al. (2025) ‘Machine learning applications for production scheduling optimization’, Journal of Exploratory Dynamic Problems, 2(4), pp. 63-79. https://edp.web.id/index.php/edp/article/view/137
3. Amadi, R.K.C. and Kabari, T.F. (2026) ‘Optimization of flow rate and head parameters in multistage centrifugal boiler feedwater pumps for improved energy efficiency in thermal power plants’, International Journal of Technology, Health and Sustainability, 2(1), pp. 238-245. https://ijths.com/wp-content/uploads/IJTHS-020181.pdf
4. Bocken, N.M.P., Short, S.W., Rana, P., et al. (2014) ‘A literature and practice review to develop sustainable business model archetypes’, Journal of Cleaner Production, 65, pp. 42–56. https://doi.org/10.1016/j.jclepro.2013.11.039
5. Bousdekis, A., Magoutas, B., Apostolou, D., et al. (2021) ‘A review of data-driven decision-making methods for Industry 4.0 maintenance applications’, Computers in Industry, 125, 103407. https://doi.org/10.1016/j.compind.2020.103407
6. Chukwumuanya, E.O., Udu, C.E. and Okpala, C.C. (2025) ‘Lean principles integration with digital technologies: A synergistic approach to modern manufacturing’, International Journal of Industrial and Production Engineering, 3(2), pp. 59-75. https://journals.unizik.edu.ng/ijipe/article/view/6006/5197
7. Chukwunedum, O.C., Okpala, C.C. and Udu, C.E. (2026) ‘A data-driven integration of total productive maintenance and Industry 4.0 technologies: A machine learning framework for predictive OEE optimization’, International Journal of Engineering Research and Development, 22(3), pp. 85–95. https://www.ijerd.com/paper/vol22-issue3/22038595.pdf
8. Despeisse, M., Ball, P.D., Evans, S., et al. (2017) ‘Industrial ecology at factory level—A conceptual model’, Journal of Cleaner Production, 31, pp. 30–39. https://doi.org/10.1016/j.jclepro.2012.02.027
9. Deswal, P. (2025) ‘Article 6 of the Paris Agreement: A comprehensive review of mechanisms, progress, and persistent challenges’, International Journal of Technology, Health and Sustainability, 1(2), pp. 111-125. https://ijths.com/wp-content/uploads/IJTHS-010235.pdf
10. Dües, C.M., Tan, K.H. and Lim, M. (2013) ‘Green as the new lean: How to use lean practices as a catalyst to greening your supply chain’, Journal of Cleaner Production, 40, pp. 93–100. https://doi.org/10.1016/j.jclepro.2011.12.023
11. Ezeanyim, O.C., Okpala, C.C. and Nwamekwe, C.O. (2026) ‘Smart cities and sustainable futures: A data-driven analysis of urban resilience’, International Journal of Technology, Health and Sustainability, 2(2), pp. 402-413. https://ijths.com/wp-content/uploads/IJTHS-0202000.pdf
12. Elkington, J. (1997) Cannibals with forks: The triple bottom line of 21^st century business. Capstone.
13. Frank, A.G., Dalenogare, L.S. and Ayala, N.F. (2019) ‘Industry 4.0 technologies: Implementation patterns in manufacturing companies’, International Journal of Production Economics, 210, pp. 15–26. https://doi.org/10.1016/j.ijpe.2019.01.004
14. Fullerton, R.R., Kennedy, F.A. and Widener, S.K. (2014) ‘Lean manufacturing and firm performance: The incremental contribution of lean management accounting practices’, Journal of Operations Management, 32(7–8), pp. 414–428. https://doi.org/10.1016/j.jom.2014.09.002
15. Garba, A. and Abdullahi, M.G. (2026) ‘Evaluation of climatic trends in Dass LGA, Bauchi State, Nigeria’, International Journal of Technology, Health and Sustainability, 2(1), pp. 52-56. https://ijths.com/wp-content/uploads/IJTHS-020147.pdf
16. Garetti, M. and Taisch, M. (2012) ‘Sustainable manufacturing: Trends and research challenges’, Production Planning and Control, 23(2–3), pp. 83–104. https://doi.org/10.1080/09537287.2011.591619
17. Gutowski, T., Dahmus, J. and Thiriez, A. (2006) ‘Electrical energy requirements for manufacturing processes’, Proceedings of the 13^th CIRP International Conference on Life Cycle Engineering, pp. 560–564).
18. Haapala, K.R., Zhao, F., Camelio, J.A., et al. (2013) ‘A review of engineering research in sustainable manufacturing’, Journal of Manufacturing Science and Engineering, 135(4), 041013. https://doi.org/10.1115/1.4024040
19. Igbokwe, N.C., Nwamekwe, C.O. and Okpala, C.C. (2026) ‘Manufacturing waste reduction through data-driven process optimization: Evidence from smart production systems’, International Journal of Technology, Health and Sustainability, 2(1), pp. 165–174. https://ijths.com/wp-content/uploads/IJTHS-020167.pdf
20. Ikiedideike, T. and Philip, S.C. (2026) ‘Predicting CNC machining errors before the first cut: A PO-ELM intelligence framework for toolpath-aware quality control in smart manufacturing’, International Journal of Technology, Health and Sustainability, 2(2), pp. 440-447. https://ijths.com/wp-content/uploads/IJTHS-0202006.pdf
21. Ihueze, C.C. and Okpala, C.C. (2012) ‘Application of Taguchi robust design as optimized lean production in manufacturing companies’, Research Journal in Engineering and Applied Sciences, 1(1), pp. 45-50. http://rjeas.emergingresource.org/issuesview.php?id=100
22. Ihueze, C.C. and Okpala, C.C. (2014) ‘The tools and techniques of lean production system of manufacturing’, International Journal of Advanced Engineering Technology, 5(4), pp. 22-27. http://technicaljournalsonline.com/ijeat/VOL%20V/IJAET%20VOL%20V%20ISSUE%20IV%20%20OCTBER%20DECEMBER%202014/Vol%20V%20Issue%20IV%20Article%205.pdf
23. Ihueze, C.C., Okpala, C.C. and Obiuto, C.C. (2011) ‘Optimal approaches to robust design for industrial wastes’, Journal of Engineering and Applied Sciences, 7, pp. 58-67
24. ISO (2006) ISO 14040: Environmental management—Life cycle assessment—Principles and framework. International Organization for Standardization.
25. Joung, C.B., Carrell, J., Sarkar, P., et al. (2013) ‘Categorization of indicators for sustainable manufacturing’, Ecological Indicators, 24, pp. 148–157. https://doi.org/10.1016/j.ecolind.2012.05.030
26. Kagermann, H., Wahlster, W. and Helbig, J. (2013) Recommendations for implementing the strategic initiative INDUSTRIE 4.0. Acatech.
27. King, A.A. and Lenox, M.J. (2001) ‘Lean and green? An empirical examination of the relationship between lean production and environmental performance’, Production and Operations Management, 10(3), pp. 244–256. https://doi.org/10.1111/j.1937-5956.2001.tb00373.x
28. Lee, J., Bagheri, B. and Kao, H.A. (2015) ‘A cyber–physical systems architecture for Industry 4.0-based manufacturing systems’, Manufacturing Letters, 3, pp. 18–23. https://doi.org/10.1016/j.mfglet.2014.12.001
29. Lee, J., Davari, H., Singh, J., et al. (2018) ‘Industrial artificial intelligence for Industry 4.0-based manufacturing systems’, Manufacturing Letters, 18, pp. 20–23. https://doi.org/10.1016/j.mfglet.2018.09.002
30. Liker, J.K. (2004) The Toyota way: 14 management principles from the world’s greatest manufacturer. McGraw-Hill.
31. Montgomery, D.C. (2017) Design and analysis of experiments. 9^th ed. Wiley.
32. Nwankwo, C.O., Okpala, C.C. and Igbokwe, N.C. (2024) ‘Enhancing smart manufacturing supply chains through cybersecurity measures’, International Journal of Engineering Inventions, 13(12), pp. 01-06. https://www.ijeijournal.com/papers/Vol13-Issue12/13120106.pdf
33. Ohno, T. (1988) Toyota production system: Beyond large-scale production. Productivity Press.
34. Okpala, C.C. (2013) ‘The status of lean manufacturing initiatives in UK small and medium-sized enterprises: A survey’, International Journal of Engineering Research and Technology, 2(10), pp. 1832-1851. http://www.ijert.org/view-pdf/5761/the-status-of-lean-manufacturing-initiatives-in-the-uk-small-and-medium-sized-enterprises–a-survey
35. Okpala, C.C. (2014) ‘Tackling muda—The inherent wastes in manufacturing processes’, International Journal of Advanced Engineering Technology, 5(4), pp. 06-11. http://technicaljournalsonline.com/ijeat/VOL%20V/IJAET%20VOL%20V%20ISSUE%20IV%20%20OCTBER%20DECEMBER%202014/Vol%20V%20Issue%20IV%20Article%202.pdf.
36. Okpala, C.C. (2026) ‘Human-centered design of jigs and fixtures: A data-driven approach to productivity, safety, and manufacturing sustainability’, International Journal of Technology, Health and Sustainability, 2(1), pp. 291-299. https://ijths.com/wp-content/uploads/IJTHS-020185.pdf
37. Okpala, C.C. and Ihueze, C.C. (2019) ‘Taguchi robust design for optimal setting of process waste parameters in an automotive parts manufacturing company’, International Journal of Industrial and Manufacturing Engineering, 13(2), pp. 101-106. https://waset.org/abstracts//97907
38. Okpala, C.C., Nwamekwe, C.O. and Onu, C.E. (2020) ‘Lean production system implementation in an original equipment manufacturing company: Benefits, challenges, and critical success factors’, International Journal of Engineering Research and Technology, 9(7), pp. 1665-1672. https://www.ijert.org/lean-production-system-implementation-in-an-original-equipment-manufacturing-company-benefits-challenges-and-critical-success-factors
39. Okpala, C.C., Nwamekwe, C.O. and Onukwuli, S.K. (2026) ‘Ergonomics in the age of Industry 5.0: A multilevel data analytics approach linking human-robot collaboration, cognitive load, and productivity in smart manufacturing systems’, International Journal of Engineering Research and Development, 22(3), pp. 59–70.
40. Okpala, C.C., Udu, C.E. and Chukwumuanya, E.O. (2025a) ‘Lean 4.0: The enhancement of lean practices with smart technologies’, International Journal of Engineering and Modern Technology, 11(6), pp. 160-173. https://iiardjournals.org/get/IJEMT/VOL.%2011%20NO.%206%202025/Lean%204.0%20The%20Enhancement%20of%20Lean%20160-173.pdf 
41. Okpala, C.C., Udu, C.E. and Onah, T.O. (2025c) ‘The role of robotics in sustainable manufacturing: Waste reduction and process optimization’, International Journal of Engineering Inventions, 14(5), pp. 16–23. https://www.ijeijournal.com/papers/Vol14-Issue5/14051623.pdf
42. Okpala, S.C., Udu, C.E. and Okpala, C.C. (2025b) ‘Lean healthcare: Patient wait times reduction and outcomes improvement’, International Journal of Health and Pharmaceutical Research, 10(7), pp. 45-59.  https://iiardjournals.org/get/IJHPR/VOL.%2010%20NO.%207%202025/Lean%20Healthcare%20Patient%20Wait%20Times%2045-59.pdf
43. Ono, C.G., Okeagu, F.N. and Chukwunedum, O.C. (2026) ‘Life cycle assessment frameworks for sustainability in digitally managed factories’, International Journal of Technology, Health and Sustainability, 2(1), pp. 253-267. https://ijths.com/wp-content/uploads/IJTHS-020183.pdf
44. Onukwuli, S.K., Okpala, C.C. and Udu, C.E. (2025) ‘The role of additive manufacturing in advancing lean production systems’, International Journal of Latest Technology in Engineering, Management and Applied Science, 14(3), pp. 179-188. https://doi.org/10.51583/IJLTEMAS.2025.140300022
45. Porter, M.E. and van der Linde, C. (1995) ‘Toward a new conception of the environment–competitiveness relationship’, Journal of Economic Perspectives, 9(4), pp. 97–118. https://doi.org/10.1257/jep.9.4.97
46. Praveen, P. (2025) ‘Life cycle assessment of municipal solid waste management scenarios in Faridabad, India’, International Journal of Technology, Health and Sustainability, 1(2), pp. 52-57. https://ijths.com/wp-content/uploads/2025/12/IJTHS-010224.pdf
47. Rother, M. and Shook, J. (2003) Learning to see: Value stream mapping to add value and eliminate muda. Lean Enterprise Institute.
48. Rothenberg, S., Pil, F.K. and Maxwell, J. (2001) ‘Lean, green, and the quest for superior environmental performance’, Production and Operations Management, 10(3), pp. 228–243.
49. Seuring, S. and Müller, M. (2008) ‘From a literature review to a conceptual framework for sustainable supply chain management’, Journal of Cleaner Production, 16(15), pp. 1699–1710.
50. Shah, R. and Ward, P.T. (2003) ‘Lean manufacturing: Context, practice bundles, and performance’, Journal of Operations Management, 21(2), pp. 129–149.
51. Tao, F., Qi, Q., Liu, A., et al. (2018) ‘Data-driven smart manufacturing’, Journal of Manufacturing Systems, 48, pp. 157–169.
52. Udu, C.E., Okpala, C.C. and Nwamekwe, C.O. (2025a) ‘Circular economy principles’ implementation in electronics manufacturing’, International Journal of Industrial and Production Engineering, 3(2), pp. 29-42. https://journals.unizik.edu.ng/ijipe/article/view/5593/5056  
53. Udu, C.E., Okpala, C.C. and Nwamekwe, C.O. (2025b) ‘Human-centric design integration in Industry 5.0’, International Journal of Industrial and Production Engineering, 3(4), pp. 18-33. https://journals.unizik.edu.ng/ijipe/article/view/6772    
54. UNIDO (2022) Industrial development report 2022: The future of industrialization in a post-pandemic world. United Nations Industrial Development Organization.
55. Voss, C., Tsikriktsis, N. and Frohlich, M. (2002) ‘Case research in operations management’, International Journal of Operations and Production Management, 22(2), pp. 195–219.
56. Womack, J.P. and Jones, D.T. (1996) Lean thinking: Banish waste and create wealth in your corporation. Simon and Schuster.
57. Yin, R.K. (2018) Case study research and applications: Design and methods. 6^th ed. Sage.