Professional Documents
Culture Documents
Keywords: Simultaneous application of lean and green practices requires adequate methods to evaluate the contribution
Lean manufacturing and effects of both paradigms on organizational performance. Thus, the objective of this study is to develop an
Green manufacturing integrated approach to evaluate the impacts of lean and green practices on organizational performance and
Analytic network process prioritize improvements in the system. To this end, this research used the Analytic Network Process (ANP) for
Assessment
the operationalization of the theoretical framework and tested it through an application in a footwear company.
By applying the assessment approach, it was possible to evaluate the lean and green systems individually and in
an integrated way through the lean-green index, a performance measure developed specifically for this work.
From a managerial perspective, this research provided a tool that enables companies to evaluate their lean and
green systems and identify which practices should be prioritized to improve operational and environmental
performance.
⁎
Corresponding author.
E-mail addresses: luanamarques.sf@hotmail.com (L.M.S. Farias), luciano@ct.ufpb.br (L.C. Santos), claudiagohr@ct.ufpb.br (C.F. Gohr),
lenilson3000@hotmail.com (L.O. Rocha).
https://doi.org/10.1016/j.resconrec.2018.12.004
Received 30 July 2018; Received in revised form 18 October 2018; Accepted 6 December 2018
Available online 24 December 2018
0921-3449/ © 2018 Elsevier B.V. All rights reserved.
L.M.S. Farias et al. Resources, Conservation & Recycling 143 (2019) 77–89
to develop an ANP-based approach for lean and green performance systems. This finding is aligned to León and Calvo-Amodio’s (2017)
assessment. In addition to making possible the prioritization of im- proposition towards a systemic view of lean and green, in which lean
provements in the system, ANP considers interdependence and feed- practices should not be implemented in isolation.
back among elements. Feedback allows judgments in any direction When it comes to the links between lean and green practices and
within the network of relationships (Saaty, 1996) and it is an important performance, some studies demonstrate empirical evidence of these
aspect of ANP to capture the interactions between lean and green. From relationships. Chiarini (2014), for example, identified how four lean
a managerial perspective, the main contribution of this research is to practices (5S, cellular manufacturing, total productive maintenance,
provide a tool that enables companies to evaluate their lean and green and setup time reduction) could help to reduce environmental impacts.
systems and identify which practices should be prioritized to improve Diaz-Elsayed et al. (2013), in another case study, used an optimization
operational and environmental performance. From the research litera- and simulation approach to assess the performance of a manufacturing
ture perspective, this study helps to reduce the gap of integration be- system affected by the application of lean and green strategies.
tween lean and green, in particular, when it comes to performance The relationships between practices and performance have also
assessment. Moreover, unlike many studies focused on lean and green been investigated by survey studies with larger samples sizes.
supply chains, this study differentiates from previous research since it Rothenberg et al. (2001), for instance, examined the relationship be-
was focused on lean and green operations, from the internal practices’ tween lean manufacturing practices and environmental performance in
point of view (Chavez et al., 2013). 31 automobile assembly plants in North America and Japan. Although
The proposed approach was tested in a footwear manufacturing they found some evidence to support the link between lean practices
plant that has successfully applied lean and green practices. Results and resource efficiency, they did not include green practices in their
were consolidated by calculating the lean-green index (LGindex), which research. Yang et al. (2011) expanded this view, including environ-
allows an integrated view of impacts on organizational performance. mental management practices in their study. Using data collected from
The lean-green index is another relevant contribution of this article 309 manufacturing firms, they provided empirical evidence that en-
since it provides a simple and unified performance measure that can be vironmental management practices represent an important mediating
easily understood by managers and researchers for self-assessment and variable to resolve the conflicts between lean manufacturing and en-
comparison purposes. vironmental performance. Likewise, Hajmohammad et al. (2013) con-
The remainder of this paper is organized as follows: initially, the firmed that the impact of lean management on environmental perfor-
theoretical background is presented for the construction of the assess- mance is mediated by environmental practices. On the other hand,
ment approach. Next, the theoretical framework for lean and green Hong et al. (2012) confirmed lean practices as an important mediator to
performance assessment is described, as well as the procedures for its achieve excellent environmental performance, but they did not include
empirical application and calculation of the lean-green index. Then, the green practices in their study. More recently, Garza-Reyes et al. (2018)
application of the framework, the calculation of the lean-green index surveyed 250 manufacturing organizations to investigate the effect of
and the sensitivity analysis are described. Subsequently, we discuss the lean practices on environmental performance. They found that the
main implications of the framework. Finally, the conclusions and sug- practices of total productive maintenance (TPM) and just-in-time (JIT)
gestions for future studies are presented. have the strongest significance on environmental performance. Finally,
by conducting empirical studies in Chinese organizations, Zhan et al.
2. Theoretical background (2018) found that the adoption of lean and green practices can lead to
better organizational performance, especially when it is moderated by
The lean system encompasses a set of interlinked operational the Chinese practice of guanxi.
practices that aim to reduce or eliminate non-value-added activities Most of the previous studies demonstrate that lean and green
throughout a product value stream (Hajmohammad et al., 2013; Jasti practices may complement each other when the focus is on improving
and Kodali, 2015). The literature demonstrates that the implementation operational and environmental performance. This complementarity
of lean practices is associated with better operational performance justifies the gap claimed in the literature for an integrated performance
(Chavez et al., 2013; Wickramasinghe and Wickramasinghe, 2017). On measurement system (Garza-Reyes, 2015; Carvalho et al., 2017; Ramos
the other hand, current studies also show that the adoption of lean et al., 2018). The premise of it is that lean and green are mutually
practices may lead to positive results for environmental performance supportive in order to achieve better performance.
(Rothenberg et al., 2001; Fercoq et al., 2016; Cherrafi et al., 2017). The previous studies on lean and green allowed us to extract prac-
However, although the lean system has provided significant benefits tices and performance criteria that have been used as variables in the
regarding environmental performance, its scope is limited and it does current research. In addition, we investigated the existence of re-
not cover all resource flows from a life-cycle perspective, such as energy lationships between different lean and green practices and performance
and water (Ball, 2015). With a focus on minimizing negative environ- criteria, regarding environmental and operational dimensions. The re-
mental impacts, the green manufacturing system appears as an appro- sults of this analysis are presented in Table 1, which shows the re-
priate approach (Verrier et al., 2014; Fercoq et al., 2016; Gandhi et al., lationships between practices and criteria. As shown in Table 1, through
2018). As an improvement approach, the green manufacturing system a literature review on lean and green, we identified criteria of opera-
is implemented through practices that limit or reduce the potential tional performance (productivity, profit, and inventory), environmental
negative impacts of the production and consumption of goods and performance (environmental impacts and energy consumption), and
services on the natural environment, thus improving the company's criteria common to both dimensions (waste reduction, cost reduction,
environmental footprint (Galeazzo et al., 2014; Verrier et al., 2014). and quality). In addition, eight lean practices (VSM, SMED, KZ, 5S,
The study of the joint adoption of lean and green practices has also TPM, SW, PP, and CM) and five green practices (EMS, LCA, 3R, DFE,
been discussed in the literature. Galeazzo et al. (2014), for example, and EEC) were selected. It is important to note that the so-called en-
investigated the synergistic effects of the interaction of lean practices vironmental management system is a general term for all certification
with green practices. This interaction was investigated through quali- and standardization systems, such as ISO 14001 and similar systems.
tative research and generated results more relevant to the im- The elements of Table 1 (criteria, practices, and relationships), identi-
plementation process than to the performance evaluation, the focus of fied from a literature review, were the basis for the development of the
this paper. From the implementation point of view, Galeazzo et al. lean and green performance assessment approach proposed in this ar-
(2014) proposed that simultaneous implementation of lean and green ticle.
practices is likely to be associated with higher operational performance Although the current literature has proved the relationship between
when compared to the sequential implementation approach of both lean and green practices and performance, management tools to
78
L.M.S. Farias et al. Resources, Conservation & Recycling 143 (2019) 77–89
Lean practices: VSM – value stream mapping; KZ – kaizen; 5S – housekeeping (seiri, seiton, seiso, seiketsu, shitsuke); SMED – setup time reduction (single minute exchange of die); SW – standardized work; PP – pull
prioritize practices to achieve specific performance objectives seem to
Pampanelli et al. (2013); Chiarini (2014); Domingo and Aguado (2015); Garza-Reyes (2015); Hallam
Prasad et al. (2016); Fercoq et al. (2016); Hallam and Contreras (2016); Thanki et al. (2016); Thanki
Miller et al. (2010); Dües et al. (2013); Pampanelli et al. (2013); Ball (2015); Kurdve et al. (2015);
Diaz-Elsayed et al. (2013); Kurdve et al. (2015); Thanki and Thakkar (2016); Thanki et al. (2016);
Yang et al. (2011); Diaz-Elsayed et al. (2013); Hajmohammad et al. (2013); Domingo and Aguado
be still missing. Nevertheless, it can be found some few noteworthy
Miller et al. (2010); Hajmohammad et al. (2013); Verrier et al. (2014); Ball (2015); Thanki et al.
initiatives in this way. Carvalho et al. (2017), for example, developed a
mathematical model to support decision making in identifying the best
set of green and lean supply chain management practices to improve
Green practices: EMS – environmental management system; LCA – life cycle assessment; 3R – reducing, reusing and recycling; DFE – design for the environment; EEC – environmental emission control.
their eco-efficiency. As it was focused in supply chains, the study of
(2015); Thanki et al. (2016); Hallam and Contreras (2016); Vinodh et al. (2016).
Carvalho et al. (2017) presented a too narrow set of lean and green
practices to be considered in the context of internal manufacturing
Garza-Reyes (2015); Thanki et al. (2016); Hallam and Contreras (2016).
practices in the model. Second, even though the joint approach of grey
based rough set and TODIM is useful for dealing with psychological
expectations, the model did not consider all possible interactions be-
tween practices. As recommended by the authors, future research may
EEC
•
DFE
More closely aligned with the aim of this study, Thanki et al. (2016)
3R
ablers. On the other hand, ANP allows for more complex relationships
5S
•
•
•
•
•
VSM
3. Methodology
•
•
•
•
•
Environmental impacts
Energy consumption
Cost reduction
Productivity
The basic assumption of this study is that lean and green can be seen
Inventory
Quality
Profit
(dimensions and determinants), and lean and green practices are con-
Environmental
79
L.M.S. Farias et al. Resources, Conservation & Recycling 143 (2019) 77–89
evaluation is usually subjective since it depends more on the perception to performance dimensions, 4) pairwise comparison matrices of en-
of decision makers than on objective measurement. Considering these ablers in relation to performance determinants, 5) pairwise comparison
three characteristics, ANP was the chosen technique for the oper- matrices between enablers, 6) supermatrix formation, and 7) calcula-
ationalization of the framework. ANP is a multicriteria analysis tech- tion of the lean-green index. In addition, we performed a sensitivity
nique that allows quantifying subjective judgments and evaluating the analysis to verify the effects on the system related to the variation of
interdependencies among the elements of a system (Saaty, 1996). weights in performance determinants. The application sequence is de-
In the ANP methodology, problems are formulated as networks, and tailed in Section 4.
not only as hierarchies, such as in the AHP. The elements of the system
are analyzed individually and in clusters, and their interdependencies 3.2. Empirical research
are analyzed in pairwise comparison matrices. The results from an ANP
model are displayed in supermatrices that allow establishing the im- In order to test the applicability of the ANP-based framework, we
pacts of the elements on the criteria and prioritizing decisions based on conducted an assessment study in a Brazilian footwear manufacturing
these impacts (Saaty, 1996). plant. It is a large factory that employs around 7000 employees to
The application procedure was divided into seven steps: 1) for- produce 670,000 pairs of rubber sandals per day. The plant was chosen
mulation of the problem, 2) comparison matrix of performance di- for having well-structured lean and green systems.
mensions, 3) pairwise comparison matrices of determinants in relation For data collection, we initially conducted semi-structured
80
L.M.S. Farias et al. Resources, Conservation & Recycling 143 (2019) 77–89
Table 2
Saaty's fundamental scale.
Source: Adapted from Saaty (1990).
interviews with company managers to obtain an overview of the system relationships (I) between components; Sikja is the relative impact of
and to identify the lean and green practices adopted. This preliminary paradigm i on the enabler k of the determinant j of the dimension a.
analysis allowed us to adjust the generic framework to the application Then, the lean-green index (LGindex) is calculated by the product of
context. Wia with the relative weight of each dimension (Ca ):
In the second phase of data collection, three respondents were se- LGindex = Wia × Ca (2)
lected for being the most appropriate people in the plant to evaluate the
lean-green system: the production manager, the lean coordinator, and
the environmental manager. Each of the respondents evaluated the is- 4. Application of the ANP framework
sues related to his/her area, and the production manager evaluated the
performance criteria at a strategic level. For this, an assessment ques- As mentioned earlier, the practical test of the framework was per-
tionnaire divided into five blocks was used, containing comparative formed in seven steps. The results of the application in a footwear
questions in pairs. manufacturing plant are presented below.
The classification of the comparative answers was based on the STEP 1: Formulation of the problem
fundamental scale of Saaty (1990), used for both ANP and AHP The construction of the lean and green performance assessment
(Table 2). It is a scale of 1–9 for comparing two components of a system started with the definition of elements that make up the evaluation
in pairwise comparison matrices. On this scale, 1 implies equal im- system and its interrelationships. The framework presented in Fig. 1
portance and 9 implies stronger importance of the row element than the was the result of the structuring of the theoretical problem. As the
column element. When the column element has stronger importance framework was constructed based on the literature, the formulation of
than the row element, a reciprocal value is assigned, where 1 represents the problem was concluded with its adaptation to the practices adopted
equal importance and 1/9 represents stronger importance. by the company.
Data obtained by the questionnaire were calculated according to Based on the initial interviews, it was identified that the lean and
traditional ANP procedures. Thus, it was possible to obtain the weights green practices that the company adopted were present in the original
of each relationship existing in the assessment framework by analyzing framework. However, the company did not use three practices designed
the comparison matrices and supermatrices generated, from which the in the framework: VSM, DFE, and LCA. Thus, these practices were ex-
results are obtained. cluded from the assessment procedure for application purposes.
STEP 2: Comparison matrix of performance dimensions
According to the proposed framework, operational and environ-
3.3. Quantifying the lean-green index (LGindex)
mental performance dimensions are at the highest hierarchical level of
the assessment system. Using a scale of one to nine, the relative im-
After the matrices were obtained, the lean-green index (LGindex) was
portance of dimensions was assessed through a single question: “with
calculated, which represents the combined impact of lean and green
regard to the importance to the company, compare the following di-
systems on organizational performance. Initially, it was obtained the
mensions of performance”. The results are shown in Table 3.
influence index (Wia ), which consists in the sum of the product of the
Although simple in numerical terms, Table 3 clearly shows the
relative importance of all weights involved. This index determines the
company's strategy of integrating operational and environmental di-
influence of each paradigm i (lean or green) on each dimension a
mensions in a balanced way. According to the ANP methodology, the e-
(operational or environmental). The equation for this index was based
Vector (Eigenvector) represents the weighted priority of each dimen-
on the studies conducted by Meade and Sarkis (1999); Agarwal et al.
sion, and the inconsistency is determined by the consistency ratio (CR),
(2006); Wong et al. (2014). Therefore:
an indicator recommended by Saaty (1996) to measure inconsistency in
J Kja
D I
judgment. According to Saaty and Kearns (1985), inconsistencies below
Wia = Pja Akja Akja Sikja 0.20 are considered tolerable.
j=1 k=1 (1)
STEP 3: Pairwise comparison matrices of determinants in relation to
where, Pja is the relative weight of determinant j on the dimension a; performance dimensions
D
Akja is the weight for enabler k of the determinant j in the dimension a In order to capture the weighted priority (e-Vector) of each de-
for the dependency relations (D) between components, that is, the de- terminant for each performance dimension (operational and environ-
pendence between the enablers in relation to each determinant, and mental), comparative questions were applied for each pair of determi-
consequently to each dimension; Akja I
is the stabilized weight for en- nants. In this evaluation, an example of a question was: “with regard to
abler k of the determinant j in the dimension a for the interdependency the importance to the company's operational performance, compare the
Table 3
Pairwise comparison matrix of performance dimensions (CR: 0.00000).
81
L.M.S. Farias et al. Resources, Conservation & Recycling 143 (2019) 77–89
Table 4
Pairwise comparisons of determinants for operational performance (CR: 0.09430).
Operational performance Inventory Profit Productivity Quality Cost reduction Waste reduction e-Vector
Table 5
Pairwise comparisons of determinants for environmental performance (CR: 0.04407).
Environmental performance Energy consumption Environmental impacts Quality Cost reduction Waste reduction e-Vector
Table 6 Table 7
Pairwise comparisons of the influence of green practices on energy consump- Pairwise comparisons between lean practices in relation to 3R (CR: 0.00942).
tion (CR: 0.00675).
3R 5S CM KZ TPM PP SMED SW e-Vector
Energy consumption 3R EEC EMS e-Vector
5S 1 5 3 5 5 5 5 0.41076
3R 1 1 7 0.45070 CM 1/5 1 1/5 1 1 1 1 0.06943
EEC 1 1 9 0.49009 KZ 1/3 5 1 3 3 3 3 0.22515
EMS 1/7 1/9 1 0.05921 TPM 1/5 1 1/3 1 1 1 1 0.07367
PP 1/5 1 1/3 1 1 1 1 0.07367
SMED 1/5 1 1/3 1 1 1 1 0.07367
criterion productivity with the criterion profit”. The response obtained SW 1/5 1 1/3 1 1 1 1 0.07367
was represented by score 7 (third column of Table 4), which indicates
that productivity was assessed as much more important than profit
when considering operational performance. STEP 6: Supermatrix formation
The relative weights of each determinant for each performance di- After the construction of individual matrices, the ANP methodology
mension can be seen in Tables 4 and 5. It is worth noting that not all proceeds with the formation of a supermatrix, in which the final scores
determinants were evaluated in both dimensions. The relationships can be evaluated globally. The supermatrix contains the e-Vectors ob-
have been previously defined in the framework presented in Fig. 1, in tained from the matrices previously elaborated. The previous matrices
which the operational dimension relates to six determinants, the en- were considered valid for the construction of the supermatrix (Table 8)
vironmental dimension relates to five determinants, and three de- since all presented inconsistencies below 0.20, as recommended by
terminants are common for both dimensions. Saaty and Kearns (1985).
STEP 4: Pairwise comparison matrices of enablers in relation to Then, the initial supermatrix is multiplied by an arbitrarily large
performance determinants number, so that the values remain stable and reach convergence, thus
The next step was to evaluate the lean and green practices (en- obtaining the final supermatrix as shown in Table 9. This supermatrix
ablers) in relation to the performance determinants, according to the contains the relative priorities of each practice, that is, the final impact
pre-established relationships in the assessment framework. Table 6 scores of each practice considering all criteria analyzed.
shows, for example, the comparison matrix of green practices in rela- The priorities of the lean and green practices in the supermatrix
tion to the determinant energy consumption. In this example, the after convergence correspond to the stabilized values of the rows in
standard question was “how intensely does the practice X contribute to Table 9. Thus, it can be verified that the practices with the greatest
energy consumption compared to the practice Y?”. Matrices such as impact on the company’s performance are EMS, 3R, 5S, and KZ. These
these were made for all performance determinants. The resulting data findings mean that the company must prioritize these practices to im-
from these matrices are synthesized in the supermatrix shown in prove its organizational performance, considering the environmental
Table 8. and operational dimensions.
STEP 5: Pairwise comparison matrices between enablers If there is any change in the priority of determinants concerning
In order to capture interdependencies between lean and green operational and environmental performance, the priority of the prac-
practices, comparison matrices between enablers were constructed. tices may also change. The influence of the variation in priority of
Thus, lean practices were compared to each other in relation to each determinants on practices is described in Section 5, where the sensi-
green practice, and vice-versa (green practices were compared to each tivity analysis is conducted.
other in relation to each lean practice). Table 7 shows, for example, the STEP 7: Calculation of the lean-green index (LGindex)
comparison matrix of lean practices in relation to the green practice 3R. The final stage of the assessment process was the calculation of the
In this case, the standard question was “compare the lean practice ‘A’ lean-green index based on Eqs. (1) and (2) presented in Section 3.3. For
with the lean practice ‘B’ in relation to 3R”. Comparing 5S with CM, for this purpose, it was necessary to create first a pairwise comparison
example, the result obtained was score 5, indicating that the practice 5S matrix (Table 10) to obtain the values of S, which correspond to the
has a stronger relationship with 3R than with CM. Analogous matrices weights of each paradigm concerning the enablers.
were constructed for the other practices, and the results were synthe- The influence indexes (Wia ) of each paradigm on the environmental
sized in the supermatrix (Table 8). and operational dimensions, calculated by Eq. 1, can be observed in
82
Table 8
Supermatrix before convergence.
83
PP SMED SW Energy consumption Inventory Environmental impacts Profit Productivity Quality Cost reduction Waste reduction
Green enablers 0.600 0.584 0.600 0.451 0 0.091 0.900 0.900 0 0 0.500
0.200 0.135 0.200 0.490 0 0.091 0 0 0 0 0
0.200 0.281 0.200 0.059 1.000 0.818 0.100 0.100 0 1.000 0.500
Lean enablers 0 0 0 0.027 0.065 0.367 0.034 0.146 0.481 0.026 0.051
0 0 0 0.102 0 0.076 0 0.082 0 0 0.067
0 0 0 0.283 0.178 0.279 0.306 0 0.405 0.273 0.249
0 0 0 0.554 0 0.233 0 0.294 0.114 0.295 0.264
0 0 0 0.034 0 0 0 0.170 0 0 0.053
0 0 0 0 0.460 0.044 0.421 0.309 0 0.295 0.264
0 0 0 0 0.300 0 0.239 0 0 0.111 0.053
Determinants 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0
Resources, Conservation & Recycling 143 (2019) 77–89
Table 9
Supermatrix after convergence.
Green enablers 3R 0.165 0.165 0.165 0.165 0.165 0.165 0.165 0.165 0.165
EEC 0.084 0.084 0.084 0.084 0.084 0.084 0.084 0.084 0.084
EMS 0.201 0.201 0.201 0.201 0.201 0.201 0.201 0.201 0.201
Lean enablers 5S 0.159 0.159 0.159 0.159 0.159 0.159 0.159 0.159 0.159
CM 0.031 0.031 0.031 0.031 0.031 0.031 0.031 0.031 0.031
KZ 0.103 0.103 0.103 0.103 0.103 0.103 0.103 0.103 0.103
TPM 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048
PP 0.031 0.031 0.031 0.031 0.031 0.031 0.031 0.031 0.031
SMED 0.027 0.027 0.027 0.027 0.027 0.027 0.027 0.027 0.027
SW 0.050 0.050 0.050 0.050 0.050 0.050 0.050 0.050 0.050
Determinants Energy consumption 0 0 0 0 0 0 0 0 0
Inventory 0 0 0 0 0 0 0 0 0
Environmental 0 0 0 0 0 0 0 0 0
impacts
Profit 0 0 0 0 0 0 0 0 0
Productivity 0 0 0 0 0 0 0 0 0
Quality 0 0 0 0 0 0 0 0 0
Cost reduction 0 0 0 0 0 0 0 0 0
Waste reduction 0 0 0 0 0 0 0 0 0
84
PP SMED SW Energy consumption Inventory Environmental impacts Profit Productivity Quality Cost reduction Waste reduction
Green enablers 0.165 0.165 0.165 0.165 0.165 0.165 0.165 0.165 0.165 0.165 0.165
0.084 0.084 0.084 0.084 0.084 0.084 0.084 0.084 0.084 0.084 0.084
0.201 0.201 0.201 0.201 0.201 0.201 0.201 0.201 0.201 0.201 0.201
Lean enablers 0.159 0.159 0.159 0.159 0.159 0.159 0.159 0.159 0.159 0.159 0.159
0.031 0.031 0.031 0.031 0.031 0.031 0.031 0.031 0.031 0.031 0.031
0.103 0.103 0.103 0.103 0.103 0.103 0.103 0.103 0.103 0.103 0.103
0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048 0.048
0.031 0.031 0.031 0.031 0.031 0.031 0.031 0.031 0.031 0.031 0.031
0.027 0.027 0.027 0.027 0.027 0.027 0.027 0.027 0.027 0.027 0.027
0.050 0.050 0.050 0.050 0.050 0.050 0.050 0.050 0.050 0.050 0.050
Determinants 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0
Resources, Conservation & Recycling 143 (2019) 77–89
L.M.S. Farias et al. Resources, Conservation & Recycling 143 (2019) 77–89
Table 10
Pairwise comparisons between paradigms and enablers.
Tables 11 and 12. The values in the second column of these tables reflect the company's strong emphasis on safety and environmental
correspond to the weights of determinants found in Table 8. The values management, with a strong focus on meeting environmental standards.
in the fourth column correspond to the weights of practices contained In spite of the interesting results, it is noteworthy to mention that
in Table 8. The values of the fifth column correspond to the stabilized the assessment process using the proposed framework was conducted to
weights of practices contained in the supermatrix after convergence test and illustrate its applicability. Therefore, the findings from the field
(Table 9). are just valid for that company, from the interviewees’ perspective.
The green paradigm appeared as the one of greatest impact on both
environmental and operational performance, with influence indexes 5. Sensitivity analysis
(Wia ) of 0.144 and 0.142, respectively. Once these indexes are obtained,
the impact of each paradigm on organizational performance (LGindex) When using ANP, the sensitivity analysis is an essential procedure
can be calculated (Eq. 2), as shown in Table 13. The results show that since it allows testing the robustness of the model in relation to the
the green paradigm has a greater impact on the company’s perfor- variation in judgments (Saaty, 1996). In this study, a sensitivity analysis
mance, with a weight of 0.143 (14.3%). According to Table 13, lean and was conducted to identify the effects of changing priorities on perfor-
green systems have, jointly, an impact of 0.230 (23.0%) on organiza- mance determinants for prioritization of lean and green practices. In
tional performance (under operational and environmental perspec- each graph in Fig. 2, the dashed vertical line in black represents the
tives). current weight of each determinant. The dashed vertical lines in red
Thus, although the lean system has a greater number of practices represent points at which the priorities of the practices change with the
implemented in the company, the green system stands out when it variation of the determinant weights.
comes to the influence on the organizational performance. These results Upon analyzing Fig. 2(a), it is observed, for example, that the
Table 11
Influence indexes for environmental performance.
Environmental performance D
Pja Akja I
Akja Sikja
85
L.M.S. Farias et al. Resources, Conservation & Recycling 143 (2019) 77–89
Table 12
Influence indexes for operational performance.
Operational D
Pja Akja I
Akja Sikja
performance
Determinants Pja Enabler D
Akja I
Akja S1 S2 Lean Green
Table 13
Lean-green impact levels on organizational performance (LGindex).
Paradigms Environmental performance Operational performance Lean-Green index (LGindex) Normalized values for LGindex
86
L.M.S. Farias et al. Resources, Conservation & Recycling 143 (2019) 77–89
Fig. 2. Sensitivity analysis: (a) energy consumption, (b) inventory, (c) environmental impacts, (d) profit, (e) productivity, (f) quality, (g) cost reduction, (h) waste
reduction.
operational and environmental performance. available on the internet (https://superdecisions.com) that implements
Another feature that makes the framework useful for performance the technique by assisting in structuring the problem and allowing
management is its flexibility. From the generic framework presented in automatic calculation. Software support greatly increases the usability
Fig. 1, each company can remove or add lean and green performance of the framework and encourages managers to use it even without prior
criteria and practices to adapt the evaluation to its context. Although training.
the components and relationships of the framework are rooted in the A relevant contribution of the proposed framework was the devel-
current literature, most of them with empirical evidence, managers opment of the lean-green index. The LGindex helps to unify the results of
interested in modifying the original structure of the assessment system the assessment, allowing incorporating this metric to the performance
will be able to do so since this paper already provides a starting point measurement system of the company. Although ANP is useful for
for that. Therefore, the assessment procedure of the theoretical frame- evaluating relationships and influences, the technique does not present
work can be considered generalizable and at the same time adaptable a unified result. With the incorporation of the LGindex, companies can
for practical application. easily track the progress of their lean and green strategies. On the other
A potential barrier to the practical application of the framework is hand, besides the unified monitoring, the detailing of the cause-effect
inherent to the ANP methodology. Although some companies may not relationships of ANP allows the identification of improvement actions
have trained personnel to use ANP, there is a free software application necessary to increase local and global performance.
87
L.M.S. Farias et al. Resources, Conservation & Recycling 143 (2019) 77–89
7. Conclusion References
This research sought to propose an original approach for the as- Agarwal, A., Shankar, R., Tiwari, M.K., 2006. Modeling the metrics of lean, agile and
sessment of lean and green practices using ANP as a fundamental leagile supply chain: an ANP-based approach. Eur. J. Oper. Res. 173, 211–225.
https://doi.org/10.1016/j.ejor.2004.12.005.
technique. To that end, through a review of the literature, it was pos- Bai, C., Satir, A., Sarkis, J., 2018. Investing in lean manufacturing practices: an en-
sible to identify practices that support the implementation of lean and vironmental and operational perspective. Int. J. Prod. Res. https://doi.org/10.1080/
green systems, as well as the related performance criteria under the 00207543.2018.1498986.
Ball, P., 2015. Low energy production impact on lean flow. J. Manuf. Technol. Manag. 26,
operational and environmental dimensions. Finally, the relationships 412–428. https://doi.org/10.1108/JMTM-12-2012-0120.
between performance criteria and practices were structured in a fra- Caldera, H.T.S., Desha, C., Dawes, L., 2017. Exploring the role of lean thinking in sus-
mework that was operationalized via ANP. The framework was tested tainable business practice: a systematic literature review. J. Clean. Prod. 167,
1546–1565. https://doi.org/10.1016/j.jclepro.2017.05.126.
in a footwear manufacturing plant, confirming that it is feasible to Carvalho, H., Govindan, K., Azevedo, S.G., Cruz-Machado, V., 2017. Modelling green and
evaluate lean and green practices regarding the impacts on operational lean supply chains: an eco-efficiency perspective. Resour. Conserv. Recycl. 120,
and environmental performance, and thus identify which practices 75–87. https://doi.org/10.1016/j.resconrec.2016.09.025.
Chaplin, L., O’Rourke, S.T.J., 2018. Could lean and green be the driver to integrate
should be prioritized. The assessment is unified through the lean-green
business improvement throughout the organisation? Int. J. Product. Perform. Manag.
index (LGindex), which brings a synthesized view of results and sim- 67, 207–219. https://doi.org/10.1108/IJPPM-01-2017-0008.
plifies the monitoring of the progress of the system. Chavez, R., Gimenez, C., Fynes, B., Wiengarten, F., Yu, W., 2013. Internal lean practices
Considering the literature on lean and green, there is a scarcity of and operational performance. Int. J. Oper. Prod. Manag. 33, 562–588. https://doi.
org/10.1108/01443571311322724.
assessment models involving both approaches. Therefore, it can be Cherrafi, A., Elfezazi, S., Govindan, K., Garza-Reyes, J.A., Benhida, K., Mokhlis, A., 2017.
stated that this study contributes to the literature of the area since it A framework for the integration of green and lean six sigma for superior sustain-
proposes an assessment structure of both systems using ANP as an im- ability performance. Int. J. Prod. Res. 55, 4481–4515. https://doi.org/10.1080/
00207543.2016.1266406.
plementation tool and providing an index (LGindex) that enables the Chiarini, A., 2014. Sustainable manufacturing-greening processes using specific lean
evaluation of lean and green systems in an integrated way. production tools: an empirical observation from European motorcycle component
Compared to other similar assessment approaches, the framework manufacturers. J. Clean. Prod. 85, 226–233. https://doi.org/10.1016/j.jclepro.2014.
07.080.
proposed in this paper is different in some ways. Unlike the model Chugani, N., Kumar, V., Garza-Reyes, J.A., Rocha-Lona, L., Upadhyay, A., 2017.
proposed by Carvalho et al. (2017), it is focused on internal manu- Investigating the green impact of Lean, Six Sigma and Lean Six Sigma. Int. J. Lean Six
facturing operations, and not on supply chains, so it addresses a more Sigma 8, 7–32. https://doi.org/10.1108/IJLSS-11-2015-0043.
Diaz-Elsayed, N., Jondral, A., Greinacher, S., Dornfeld, D., Lanza, G., 2013. Assessment of
appropriate set of practices and performance criteria for this context. It lean and green strategies by simulation of manufacturing systems in discrete pro-
links practices to specific performance criteria and considers lean and duction environments. CIRP Ann. Manuf. Technol. 62, 475–478. https://doi.org/10.
green as components of the same integrated system. However, the most 1016/j.cirp.2013.03.066.
Domingo, R., Aguado, S., 2015. Overall environmental equipment effectiveness as a
remarkable characteristic of the proposed approach is that it considers
metric of a lean and green manufacturing system. Sustain 7, 9031–9047. https://doi.
all possible interactions between practices and performance criteria, a org/10.3390/su7079031.
gap left by Thanki et al. (2016); Carvalho et al. (2017); Ramos et al. Dües, C.M., Tan, K.H., Lim, M., 2013. Green as the new lean: how to use lean practices as
(2018); Bai et al. (2018). a catalyst to greening your supply chain. J. Clean. Prod. 40, 93–100. https://doi.org/
10.1016/j.jclepro.2011.12.023.
Particularly, this article had an objective similar to that proposed by Fercoq, A., Lamouri, S., Carbone, V., 2016. Lean/green integration focused on waste
Thanki et al. (2016), which focused on small and medium-sized en- reduction techniques. J. Clean. Prod. 137, 567–578. https://doi.org/10.1016/j.
terprises (SMEs). However, in addition to having a broader scope (fo- jclepro.2016.07.107.
Galeazzo, A., Furlan, A., Vinelli, A., 2014. Lean and green in action: interdependencies
cusing not only on SMEs), this study goes beyond the work of Thanki and performance of pollution prevention projects. J. Clean. Prod. 85, 191–200.
et al. (2016) in three ways: (i) it evaluates interrelationships between https://doi.org/10.1016/j.jclepro.2013.10.015.
practices and performance criteria in a network, and not only in hier- Gandhi, N.S., Thanki, S.J., Thakkar, J.J., 2018. Ranking of drivers for integrated lean-
green manufacturing for Indian manufacturing SMEs. J. Clean. Prod. 171, 675–689.
archies, allowing feedback among the elements; (ii) it provides an in- https://doi.org/10.1016/j.jclepro.2017.10.041.
strument for a practical application, which enables companies to self- Garza-Reyes, J.A., 2015. Lean and green: a systematic review of the state of the art lit-
assess their performance; and (iii) it proposes a unified performance erature. J. Clean. Prod. 102, 18–29. https://doi.org/10.1016/j.jclepro.2015.04.064.
Garza-Reyes, J.A., Kumar, V., Chaikittisilp, S., Tan, K.H., 2018. The effect of lean methods
indicator (LGindex).
and tools on the environmental performance of manufacturing organisations. Int. J.
Regarding the limitations of the research, it is important to consider Prod. Econ. 200, 170–180. https://doi.org/10.1016/j.ijpe.2018.03.030.
that the existing relationships in the framework were based solely on Hajmohammad, S., Vachon, S., Klassen, R.D., Gavronski, I., 2013. Lean management and
supply management: their role in green practices and performance. J. Clean. Prod.
literature analysis. Future studies could analyze the elements contained
39, 312–320. https://doi.org/10.1016/j.jclepro.2012.07.028.
in the framework through factorial analysis to confirm the relationships Hallam, C., Contreras, C., 2016. Integrating lean and green management. Manag. Decis.
obtained from the literature. Another opportunity for improvement in 54, 2157–2187. https://doi.org/10.1108/MD-04-2016-0259.
the framework is to measure the level of integration between lean and Hong, P., Roh, J.J., Rawski, G., 2012. Benchmarking sustainability practices: evidence
from manufacturing firm. Benchmarking Int. J. 19, 634–648. https://doi.org/10.
green practices applied to a company in order to identify synergies 1108/MRR-09-2015-0216.
between both systems. Another path for the continuity of this research Jasti, N.V.K., Kodali, R., 2015. Lean production: literature review and trends. Int. J. Prod.
is to combine ANP with other multicriteria analysis techniques that take Res. 53, 867–885. https://doi.org/10.1080/00207543.2014.937508.
Kurdve, M., Shahbazi, S., Wendin, M., Bengtsson, C., Wiktorsson, M., 2015. Waste flow
into account the relationships between the elements of a system, such as mapping to improve sustainability of waste management: a case study approach. J.
Graph-Theoretic Approach (GTA) or Interpretive Structural Modeling Clean. Prod. 98, 304–315. https://doi.org/10.1016/j.jclepro.2014.06.076.
(ISM), in order to enrich the results generated. León, H.C.M., Calvo-Amodio, J., 2017. Towards lean for sustainability: understanding the
interrelationships between lean and sustainability from a systems thinking perspec-
Regarding the practical application, future works could apply the tive. J. Clean. Prod. 142, 4384–4402. https://doi.org/10.1016/j.jclepro.2016.11.
focus group technique to the decision-makers to test the convergence in 132.
judgments. Furthermore, it is always noteworthy to recommend the Meade, L.M., Sarkis, J., 1999. Analyzing organizational project alternatives for agile
manufacturing processes: an analytical network approach. Int. J. Prod. Res. 37,
extension of the number of practical applications to understand the 241–261. https://doi.org/10.1080/002075499191751.
limits of applicability of the proposed framework.
88
L.M.S. Farias et al. Resources, Conservation & Recycling 143 (2019) 77–89
Miller, G., Pawloski, J., Standridge, C., 2010. A case study of lean, sustainable manu- implementation practices in Indian SMEs using analytical hierarchy process (AHP)
facturing. J. Ind. Eng. Manag. 3, 11–32. https://doi.org/10.3926/jiem.2010.v3n1. approach. J. Clean. Prod. 135, 284–298. https://doi.org/10.1016/j.jclepro.2016.06.
p11-32. 105.
Pampanelli, A.B., Found, P., Bernardes, A.M., 2013. A lean & green model for a pro- Verrier, B., Rose, B., Caillaud, E., Remita, H., 2014. Combining organizational perfor-
duction cell. J. Clean. Prod. 85, 19–30. https://doi.org/10.1016/j.jclepro.2013.06. mance with sustainable development issues: the lean and green project benchmarking
014. repository. J. Clean. Prod. 85, 83–93. https://doi.org/10.1016/j.jclepro.2013.12.
Prasad, S., Khanduja, D., Sharma, S.K., 2016. An empirical study on applicability of lean 023.
and green practices in the foundry industry. J. Manuf. Technol. Manag. 27, 408–426. Vinodh, S., Ramesh, K., Arun, C.S., 2016. Application of interpretive structural modelling
https://doi.org/10.1108/JMTM-08-2015-0058. for analysing the factors influencing integrated lean sustainable system. Clean
Ramos, A.R., Ferreira, J.C.E., Kumar, V., Garza-Reyes, J.A., Cherrafi, A., 2018. A lean and Technol. Environ. Policy 18, 413–428. https://doi.org/10.1007/s10098-015-1025-7.
cleaner production benchmarking method for sustainability assessment: a study of Wickramasinghe, G., Wickramasinghe, V., 2017. Implementation of lean production
manufacturing companies in Brazil. J. Clean. Prod. 177, 218–231. https://doi.org/ practices and manufacturing performance: the role of lean duration. J. Manuf.
10.1016/j.jclepro.2017.12.145. Technol. Manag. 28, 531–550. https://doi.org/10.1108/JMTM-08-2016-0112.
Rothenberg, S., Pil, F.K., Maxwell, J., 2001. Lean, green, and the quest for superior en- Womack, J.P., Jones, D.T., Roos, D., 1990. The Machine That Changed the World. Rawson
vironmental performance. Prod. Oper. Manag. 10, 228–243. https://doi.org/10. Associates, New York 323 pp.
1111/j.1937-5956.2001.tb00372.x. Wong, W.P., Ignatius, J., Soh, K.L., 2014. What is the leanness level of your organisation
Saaty, T.L., 1990. How to make a decision: the analytic hierarchy process. Eur. J. Oper. in lean transformation implementation? An integrated lean index using ANP ap-
Res. 48, 9–26. https://doi.org/10.1016/0377-2217(90)90057-I. proach. Prod. Plan. Control 25, 273–287. https://doi.org/10.1080/09537287.2012.
Saaty, T.L., 1996. Decision Making With Dependence and Feedback: the Analytic Network 674308.
Process. RWS Publications, Pittsburgh 370 pp. Yang, M.G., Hong, P., Modi, S.B., 2011. Impact of lean manufacturing and environmental
Saaty, T.L., Kearns, K.P., 1985. Analytic Planning: the Organization of Systems. Pergamon management on business performance: an empirical study of manufacturing firms.
Press, Oxford 208 pp. Int. J. Prod. Econ. 129, 251–261. https://doi.org/10.1016/j.ijpe.2010.10.017.
Thanki, S.J., Thakkar, J.J., 2016. Value-value load diagram: a graphical tool for lean- Zhan, Y., Tan, K.H., Ji, G., Chung, L., Chiu, A.S.F., 2018. Green and lean sustainable
green performance assessment. Prod. Plan. Control 27, 1280–1297. https://doi.org/ development path in China: guanxi, practices and performance. Resour. Conserv.
10.1080/09537287.2016.122064. Recycl. 128, 240–249. https://doi.org/10.1016/j.resconrec.2016.02.006.
Thanki, S., Govindan, K., Thakkar, J., 2016. An investigation on lean-green
89