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Driving Sustainable Operations: Aligning Lean Six Sigma Practices with Sustainability Goals

Author

Listed:
  • Pedro Marques

    (Industrial Engineering and Management, Faculty of Engineering, Lusófona University, Campo Grande, 1749-024 Lisbon, Portugal
    RCM2+ Research Centre for Asset Management and Systems Engineering, Lusófona University, Campo Grande, 376, 1749-024 Lisbon, Portugal)

  • Lígia Conceição

    (School of Business Administration, Polytechnic Institute of Setúbal, 2914-504 Setúbal, Portugal
    LIACC–Artificial Intelligence and Computer Science Laboratory, Department of Informatics Engineering, Faculty of Engineering, University of Porto, Rua Dr. Roberto Frias, 4200-465 Porto, Portugal)

  • André M. Carvalho

    (UNIDEMI—Research and Development Unit for Mechanical and Industrial Engineering, Department of Mechanical and Industrial Engineering, NOVA School of Science and Technology, Universidade NOVA de Lisboa, 2829-516 Caparica, Portugal
    Laboratório Associado de Sistemas Inteligentes—LASI, 4800-058 Guimarães, Portugal)

  • João Reis

    (Industrial Engineering and Management, Faculty of Engineering, Lusófona University, Campo Grande, 1749-024 Lisbon, Portugal
    RCM2+ Research Centre for Asset Management and Systems Engineering, Lusófona University, Campo Grande, 376, 1749-024 Lisbon, Portugal)

Abstract

Sustainability is gaining relevance across organizations, yet significant challenges remain in how it is implemented and translated into daily operations. This paper examines how Lean Six Sigma can be used to address operational challenges while also supporting the integration of sustainability objectives in industrial contexts. The study is based on a project conducted in a fish processing plant, aiming to increase production capacity and reduce delays. Using the DMAIC framework, the team addressed key bottlenecks through demand-based workload leveling, earlier production planning, and targeted maintenance to improve equipment performance. These actions led to measurable gains in throughput, resource use, and schedule reliability. In parallel, they contributed to sustainability outcomes, including reduced rework, lower waste, and improved working conditions. The results suggest that Lean Six Sigma, typically focused on performance, can also act as a platform for embedding sustainability into existing routines. The findings offer insight into how performance-driven approaches can support sustainability transitions in process-intensive industries.

Suggested Citation

  • Pedro Marques & Lígia Conceição & André M. Carvalho & João Reis, 2025. "Driving Sustainable Operations: Aligning Lean Six Sigma Practices with Sustainability Goals," Sustainability, MDPI, vol. 17(19), pages 1-23, October.
    • Handle: RePEc:gam:jsusta:v:17:y:2025:i:19:p:8898-:d:1766087
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    References listed on IDEAS

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