Lean and Green Combine To Impact Environmental and Operational Performance
Lean and Green Combine To Impact Environmental and Operational Performance
To cite this article: R. Anthony Inman & Kenneth W. Green (2018): Lean and green combine to
impact environmental and operational performance, International Journal of Production Research,
DOI: 10.1080/00207543.2018.1447705
We assess the antecedent link between lean and green practices and assess the combined impact of lean and green prac-
tices on both environmental and operational performance. A lean and green practices performance model is proposed that
incorporates lean and green practices as antecedents to both environmental and operational performance. Structural equa-
tion modelling was used to analyse data collected from a sample of 182 manufacturing managers in U.S. plants. We
found that lean manufacturing practices are positively associated with environmental performance and operational perfor-
mance and that green supply chain management practices are positively associated with environmental performance and
environmental performance is positively associated with operational performance. No support was found for the idea that
green supply chain management practices are positively associated with operational performance. While lean practices
were found to directly affect environmental performance, the indirect effect of lean practices on environmental perfor-
mance through green practices is stronger, indicating complementarity.
Keywords: advanced manufacturing processes; environmentally friendly manufacturing; lean manufacturing; green
manufacturing; structural equation modelling; sustainable manufacturing; complementarity
1. Introduction
Manufacturing organisations have begun to adopt environmentally sustainable practices in response to increasing
demand from customers for eco-friendly products and services (Green, Toms, and Clark 2015). The positive association
between environmental sustainability strategy and environmental and organisational performance is well established in
the literature (Green et al. 2012). Yet, an extensive literature review suggests that lean and green practices may not
always be compatible (Mollenkopf et al. 2010).
Considering that customers demand environmental sustainability and that environmental sustainability leads to
improved organisational performance, it is now important to identify necessary antecedents to the successful implemen-
tation of environmental sustainability practices. Since lean manufacturing practices aim to eliminate all forms of waste
(Pavnaskar, Gershenson, and Jambekar 2013) and green supply chain management practices aim to specifically eliminate
environmental wastes (Zhu, Sarkis, and Lai 2008; Green et al. 2012), it is logical to argue that having lean practices in
place will support the successful implementation of green supply chain management practices. We propose that firms
that have successfully implemented lean practices are better able to successfully implement the more environmentally
focused green practices.
It is our purpose to fill a gap in the literature identified by Hallam and Contreras (2016) by providing an empirical
integrated operating model of the firm relating lean and green. We assess the antecedent link between lean and green
practices and assess the combined impact of lean and green practices on both environmental and operational perfor-
mance. A lean and green practices performance model is proposed that incorporates lean and green practices as antece-
dents to both environmental and operational performance. To facilitate assessment of the model, data collected from a
sample of 182 manufacturing managers working in U.S. manufacturing plants are analysed using a structural equation
modelling methodology.
The literature associated with lean and green practices and the impact of those practices on environmental and opera-
tional performance is briefly summarised in the justification of the study with more detail appearing later with the sup-
port for the model and hypotheses. Subsequent sections include a description of the methodology employed to answer
the research question, a presentation and interpretation of the statistical results related to assessment or the validity and
reliability of the measurement scales employed and the assessment of the structural model. Finally, conclusions are
developed and discussed.
2. Theoretical background
Complementarity Theory (Milgrom and Roberts 1990; Bergmiller and McCright 2009; Narasimhan, Swink, and Viswa-
nathan 2010) serves as the theoretical underpinning of this study. Lean manufacturing practices and green supply chain
management practices are organisational competencies or resources that result in competitive advantage when adopted
by manufacturing firms. Lean practices and green practices are not easily implemented, requiring strategic focus, culture
modification and significant investment. Lean practices and green practices are complementary in that the implementa-
tion of one set of practices supports the implementation of the other set of practices and this combination of practices
leads to a levels of improved environmental and operational performance that could not be achieved through the imple-
mentation of either set of practices alone.
Fundamentally, lean manufacturing practices related to suppliers, customers, setup times, pull systems, preventive
maintenance, employee involvement, statistical process control and continuous flow are designed to eliminate all forms
of waste throughout the supply chain (Shah and Ward 2007). The green supply chain management practices specified
by Zhu, Sarkis, and Lai (2008) are specifically designed to eliminate environmental wastes. We argue that lean practices
and green practices combine to form a resource advantage for adopting firms. Firms with such combined capabilities
gain advantage over competitors based on the general ability to eliminate all forms of waste and the specific ability to
eliminate environmental wastes. These abilities allow firms to provide customers with eco-friendly products and services
that are produced through environmentally sustainable processes at relatively low costs.
We further argue that lean manufacturing practices and green supply chain management practices are complementary
in that waste elimination capabilities emanating from lean practices will enhance a firm’s ability to successfully imple-
ment green supply chain management practices giving it the additional capability to reduce and/or eliminate environ-
mental wastes associated with its production processes and its products and services. Lean practices and green practices
are complementary and synergistic in their impact on environmental and operational performance. This synergy is
reflected in the positive impact of implementation of lean practices on the results of mutually or subsequently imple-
mented green practices. More lean leads to more green or vice versa.
implemented concurrently (Klassen 2000; King and Lenox 2001; Miller, Pawloski, and Standridge 2010; Azevedo et al.
2012; Ng, Low, and Song 2015; Garza-Reyes et al. 2016).
Despite Hajmohammad et al.’s (2013) observation that ‘very few studies (if any) have simultaneously addressed
environmental management practices, operation/supply chain systems, and environmental performance’, Hallam and
Contreras (2016) managed to review 60 articles representing ‘the most relevant peer-reviewed journal publications cov-
ering the integration of Lean and Green management’ and noted that most were case studies or conceptual papers with
only ten being surveys. They feel that there is little evidence of combined lean and green implementation but the pur-
ported synergy between the two is evident in the postulate of some articles. Specifically, they note that an integrated
model of the firm relating lean and green is lacking. Along the same lines, Jabbour et al. (2016) note that the literature
has yet to reach a definitive consensus on the necessity to integrate green issues in operations for firms to achieve better
performance. Thus, the implication is that research on lean/green issues is still under-examined (Piercy and Rich 2015),
especially research utilising survey data.
With the exception of one journal article (Green et al. 2012) and one dissertation (Lee 2013) no research was found
examining the relationship between environmental performance and operational performance. While much of this work
replicates previous published work (the relationship between lean practices and green practices, lean practices and envi-
ronmental performance, green practices and environmental performance and green practices and operational perfor-
mance), we find it necessary to revisit these areas to arrive at the unexplored relationship between environmental
performance and operational performance, thereby providing a more integrated empirical model.
4. Literature review
4.1 Lean practices
Lean manufacturing has seen wide use and a broad scope of interests over the last 40 years. Emiliani (2006) notes that
it has been an important route for improving business performance since the late 1970’s although the term ‘lean’ was
first used in scholarly research by Krafcik (1988). Interest in the topic became widespread with the publication of The
Machine That Changed the World (Womack, Jones and Roos 1990) in 1990. Jasti and Kodali (2015) note that 546
research articles in 24 operations research journals were published from 1988 to 2011 so the literature on lean is very
deep and does not bear repeating here. Jasti and Kodali (2015), Gupta and Jain (2013) and Stone (2012) provide com-
prehensive reviews of the literature regarding lean manufacturing.
Over the years lean manufacturing has gone through an evolution of refinement of its principles and practices to a
lean business system (Marodin and Saurin 2013). Its main purpose is to produce products without any kind of waste,
with waste defined as anything that adds cost from overproduction, waiting, poor quality or unnecessary processing,
transportation or inventory, but adds no value. The practices of Just-in-Time, Total Quality Management, Total Preven-
tive Maintenance and Human Resource Management ‘bundled’ together make up lean production (Shah and Ward
2003).
the implementation of green manufacturing practices. Drohomeretski, Gouvea, and Pinheiro (2014) provide anecdotal
evidence that the primary motivation for the implementation of green supply chain management practices in the Brazil-
ian Auto Industry is an emphasis on cost reduction through programmes such as lean manufacturing. Companies adopt-
ing lean manufacturing practices are also likely to implement green supply chain management practices. Sarkis (2012)
argues that both lean and green initiatives focus on the elimination of wastes throughout the supply chain. Utilising a
conceptual framework (Simpson and Power 2005; Pampanelli, Found, and Bernardes 2014) case study (Azevedo et al.
2012), secondary data (Yang, Hong, and Modi 2011) and literature review (Mollenkopf et al. 2010) a positive relation-
ship has been shown to exist between lean practices and green practices. By analysing survey data from a sample of
Canadian manufacturing plants, Hajmohammad et al. (2013) found the level of lean management activities to be posi-
tively associated with the extent of environmental practices.
Finally, a meta-analysis by Golicic and Smith (2013) confirmed that environmental supply chain practices positively
influenced operational-based measures of performance.
5. Hypotheses
In addition to results of conceptual work (Simpson and Power 2005; Pampanelli, Found, and Bernardes 2014), a case
study (Azevedo et al. 2012), use of secondary data (Yang, Hong, and Modi 2011) and literature review (Mollenkopf
et al. 2010) and a Canadian survey (Hajmohammad et al. 2013), we propose to expand the body of knowledge by utilis-
ing survey data from U.S. manufacturing firms. We propose that:
H1: Lean manufacturing practices are positively associated with green supply chain management practices.
Further survey research, specifically utilising firms from a different country (U.S.), could supplement past findings and
help to clarify conflicting findings in research regarding lean practices and environmental performance. Since lean manu-
facturing incorporates systems, processes and practices that support the elimination of all forms of waste and existence
of these systems, processes and practices should enhance and support an organisation’s ability to implement green prac-
tices that are specifically designed to eliminate environmental wastes, we propose that:
H2: Lean manufacturing practices are positively associated with environmental performance.
In support of findings from scarce survey-based studies regarding the relationship between green supply chain manage-
ment practices and environmental performance (Zhu and Sarkis 2004; Hajmohammad et al. 2013; Lai and Wong 2012;
Lee 2013; Jabbour et al. 2016) and even scarcer survey-research utilising data from U.S. firms (Green et al. 2012), we
theorise that green supply chain management practices are antecedent to environmental performance:
H3: Green supply chain management practices are positively associated with environmental performance.
The association between lean manufacturing practices and performance has been widely researched as evidenced by an
exhaustive literature review of the subject by Negrao, Godinho Filho, and Marodin (2017). They found 41 articles that
suggested a positive effect of lean practices in at least one operational, financial and/or environmental performance met-
ric and only three studies that indicated some lean practices had a negative effect on operational or financial perfor-
mance. Even though it has been highly researched previously, we include this relationship in our study as it is
embedded in the theorised model. Therefore:
H4: Lean manufacturing practices are positively associated with operational performance.
Even though there are previous studies regarding the relationship between green supply chain practices and operational
performance (see Literature Review), this work includes the same in order to provide a more complete integrated model.
Therefore, in replication of previous studies, but uniquely using data from U.S. firms, we propose that:
H5: Green supply chain management practices are positively associated with operational performance.
Using complementarity theory we argue that, together, lean manufacturing practices and green supply chain management
practices will synergistically produce superior results. Only Green et al. (2012) and Lee (2013) have researched the
impact of environmental performance on operational performance. Green et al. (2012) found a positive impact of envi-
ronmental performance on operational performance while Lee (2013) reported finding a significant link from environ-
6 R.A. Inman and K.W. Green
mental performance to operational performance. Taken together, logic and these results support the claim that environ-
mental performance is positively associated with operational performance. Hence:
6. Theorised model
The theoretical model is displayed in Figure 1. The model incorporates four constructs and six hypotheses. The con-
structs definitions as they are applied in this study are presented in Table 1. All hypothesised relationships are positive.
The model is designed to facilitate assessment of the combined impact of lean manufacturing practices and green supply
chain management practices on environmental sustainability.
7. Methodology
This study uses a well-established survey methodology (Inman et al. 2011; Green et al. 2012) in which the data collec-
tion is managed by a third-party data collection service. A structural equation modelling (SEM) methodology is fol-
lowed to analyse the assembled data-set, test the individual hypotheses within the model and to assess the fit of the
theorised model to the data. Partial Least Squares SEM is used to specifically test each of the hypotheses within the
model as recommended by Wetzels, Odekerken-Schröder, and van Oppen (2009) and in a manner consistent that found
in the existing literature (Clark, Toms, and Green 2014; Green et al. 2017). Akter, Wamba, and Dewan (2017) recom-
mend using PLS/SEM for assessing complex structural models to facilitate completeness and capture reality. SmartPLS
2.0 software (Ringle, Wende, and Will 2005) is used to conduct the PLS analysis. Co-variance-based SEM (Lisrel 8.8)
is used to assess the fit of the overall model. The use of co-variance-based SEM to assess overall model fit is also well
established in the literature (Inman et al. 2011; Green et al. 2012). This combination of SEM methods is based on
descriptions of the appropriate uses of PLS and co-variance-based SEM (PLS for hypothesis testing and co-variance
based for model testing) by Hair, Ringle, and Sarstedt (2011). Using both PLS and co-variance-based approaches sup-
ports the appropriate testing of individual hypotheses within the context of a structural model and also the appropriate
assessment of the overall fit of the structural model. It is also interesting to compare the results of the alternative SEM
methods.
LEAN
H4: (+)
H2: (+)
H3: (+)
H5: (+)
GSCMP
Construct Definition
Green Supply Chain A management improvement programme comprised of internal environmental management, green
Management Practices purchasing, cooperation with customers, eco-design and investment recovery practices designed to
integrate and coordinate the environmental sustainability efforts of all supply chain partners for the
purpose of eliminating all forms of environmental waste from supply chain processes (Zhu, Sarkis,
and Lai 2008; Green et al. 2012)
Lean Manufacturing Practices A management improvement programme comprised of lean practices with suppliers and customers
that emphasise setup time reduction, pull systems, continuous flow, statistical process control,
preventive maintenance and employee involvement designed to eliminate all forms of waste from
all supply chain processes (Shah and Ward 2003, 2007)
Environmental Performance Environmental performance relates the ability of manufacturing plants to reduce air emissions,
effluent waste and solid wastes and the ability to decrease consumption of hazardous and toxic
materials (Zhu, Sarkis, and Lai 2008)
Operational Performance Operational performance relates to the manufacturing plant’s capabilities to more efficiently
produce and deliver products to customers (Zhu, Sarkis, and Lai 2008)
Title Number
Owner 7
Vice-President 38
Plant Manager 10
Operations Manager 56
Purchasing Manager 17
Logistics Manager 13
Maintenance Manager 3
Sales Manager 4
Engineering Manager 8
Industrial Waste Manager 2
Inventory Manager 1
Quality Manager 7
Research and Development Manager 1
Other Manager 15
Total 182
Industry Category
Food Manufacturing 14
Beverage and Tobacco Product Manufacturing 3
Textile Mills 6
Apparel Manufacturing 1
Wood Product Manufacturing 3
Paper Manufacturing 1
Printing and Related Support Activities 6
Petroleum and Coal Products Manufacturing 2
Chemical Manufacturing 16
Plastics and Rubber Products Manufacturing 6
Non-metallic Mineral Product Manufacturing 2
Primary Metal Manufacturing 7
Fabricated Metal Product Manufacturing 18
Machinery Manufacturing 18
Computer and Electronic Product Manufacturing 7
Electrical Equipment, Appliance and Component Manufacturing 9
Transportation Equipment Manufacturing 11
Miscellaneous Manufacturing 52
Total 182
Mean Years in Current Position 11.53
Mean Number of Plant Employees 964.07
8 R.A. Inman and K.W. Green
8. Results
8.1 PLS/SEM results
A PLS/SEM statistical analysis methodology is employed because of the use of second-order constructs in the model
and because our primary objective is to test the hypotheses in the model. PLS results are displayed in Figure 2 and sup-
port for the hypotheses is summarised in Table 4. Hypotheses 1 through 4 (LEAN → GSCMP, LEAN → ENVPERF,
GSCMP → ENVPERF, LEAN → OPERPERF) and 6 (ENVPERF → OPERPERF) are supported. Hypothesis 5
(GSCMP → OPERPERF) is not supported.
International Journal of Production Research 9
Variables CA CR AV CC ED GP IE IR LC LE LF LM LP LS LT LW EP OP
Notes: CA – Cronbach’s Alpha; CC – Cooperation with Customers; CR – Composite Reliability; ED – Eco-design; AV – Average
Variance Extracted; GP – Green Purchasing; EP – Environmental Performance; IE – Internal Environmental Management; OP – Oper-
ational Performance; IR – Investment Recovery; LS – Lean Statistical Process Control; LC – Lean with Customers; LP – Lean Pull
Production; LF – Lean Continuous Flow; LT – Lean Setup; LE – Lean Employee Involvement; LM – Lean Preventive Maintenance;
LW – Lean with Suppliers.
Square root of average variance extracted in bold on diagonal.
Notes: LEAN – Lean manufacturing; GSCMP – Green supply chain management practices; ENVPERF – Environmental performance;
OPERPERF – Operational performance.
**sig. at 0.01 level.
*sig. at 0.05 level.
ns
non-significant.
LEAN
+0.44**
+0.24* R2 = .47 R2 = .53
+0.81** ENVPERF +0.45** OPERPERF
+0.48**
-0.06 ns
GSCMP
R2 = .66
LEAN
+0.39**
+0.22 ns R2 = .55 R2 = .61
+0.82** ENVPERF +0.49** OPERPERF
+0.55**
-0.03 ns
GSCMP
R2 = .67
*Although lean practices directly affected environmental performance, the indirect effect of lean on environmental performance was
stronger, i.e. lean and green are complementary.
**Indicates an indirect association between green practices and operational performance through environmental performance. See Sec-
tion 9.1.
International Journal of Production Research 11
Lean manufacturing practices combine with green supply chain management practices to positively impact both
environmental performance and operational performance. Forty-seven per cent of the variation in environmental perfor-
mance is explained by the variation in lean practices and green practices combined. The successful implementation of
lean practices supports implementation of green practices. The association is positive and very strong. The strong posi-
tive association is expected since green practices have formed as a subset of lean practices. Lean practices are aimed at
eliminating all forms of waste throughout the supply chain, while green practices are focused on the elimination of envi-
ronmental wastes as a specific category of wastes. Although the PLS results indicate that lean practices directly affect
environmental performance, the indirect effect of lean practices on environmental performance through green practices
is stronger which indicates complementarity. The direct effect is +0.24 (sig. at the 0.05 level), while the indirect effect
is +0.39 (+0.81 times +0.48; sig. at the 0.01 level).
Fifty-three per cent of the variation in operational performance is explained by the combined impact of lean prac-
tices, green practices and environmental performance. Lean practices both directly and indirectly impact operational per-
formance. The direct effect (+0.44) is positive, moderately strong and significant at the 0.01 level. The indirect effect
(+0.11 = +0.24 times +0.45) of lean practices through environmental performance is positive, weak and significant at
the 0.05 level. Importantly, the PLS/SEM results indicate that the effect of green practices on operational performance is
indirect through environmental performance, rather than direct. The indirect effect of +0.22 (+0.48 times +0.45) is posi-
tive and significant at the 0.01 level.
9. Conclusions
9.1 Discussion of findings
We argue that lean manufacturing practices are positively associated with green supply chain management practices.
Consistent with past research we found support for the proposals that lean manufacturing practices are positively
associated with green supply chain management practices, lean manufacturing practices are positively associated with
environmental performance, green supply chain management practices are positively associated with environmental per-
formance, lean manufacturing practices are positively associated with operational performance. Noteworthy is the find-
ing that, although the PLS results indicate that lean practices directly affect environmental performance, the indirect
effect of lean practices on environmental performance through green practices was stronger supporting our claim that
lean practices and green practices are complementary. The primary contribution of this study, is the finding that no sup-
port was found for the idea that green supply chain management practices are positively associated with operational per-
formance. This is in contrast to past research (see Table 5) utilising survey data from Brazil (Jabbour et al. 2016), China
(Lai and Wong 2012; Yu et al. 2014), India (Mitra and Datta 2014) and Korea (Lee 2013). However, environmental per-
formance is found to be positively associated with operational performance, indicating an indirect association between
green practices and operational performance through environmental performance. In other words, improvement in opera-
tional performance does not come directly from implementation of green practices but rather from improving environ-
mental performance as a result of implementation of green practices. At first glance, this is circular logic, but, it
suggests that firms merely adding green practices to lean practices without an improvement in environmental perfor-
mance may not be receiving the full benefit of the complementarity between lean and green practices. Despite the com-
patibility of the two sets of practices, firms can still fail to strategically capitalise on the environmental benefits that are
a by-product of lean processes (Larson and Greenwood 2004). For example, Boeing had significant difficulty applying
lean to environmental processes (Larson and Greenwood 2004). Green practices implementation can result in some firms
12 R.A. Inman and K.W. Green
outperforming others as a result of their ability to leverage their resources and possibly possession of a unique set of
resources (Shi et al. 2012) as is consistent with the resource-based view (RBV).
The literature indicates that lean transformations appear to be more successful when aligned throughout the enter-
prise (Stone 2012). ‘Side-by-side’ green and lean practices may fail to realise the competitive advantage of the comple-
mentarity provided by fully integrated systems by concentrating ‘on what is the same about sustainable supply chain
management with much less emphasis on what, if anything, might be truly unique’. (Pagell and Wu 2009) Carter and
Rogers (2008) state that ‘… organisations that become sustainable enterprises do not simply overlay sustainability initia-
tives with corporate strategies’. Measures of environmental performance should be included in any integrated model of
lean practices and green practices to ensure that improvements in operational performance are realised as an indirect
product of green practices (through environmental performance) rather than from some other strategic initiative, e.g.
lean. The same holds true for negative results arising from integrating lean and green practices. Failure to classify lean
properly can make it difficult to identify sustainability benefits leading to the identification of incorrect negative associa-
tions (Piercy and Rich 2015) whereas direct measurement of environmental performance could preclude this.
Lean practices and green practices are organisational competencies that combine to reduce product and service costs
through the elimination of wastes and enhance environmental sustainability by supporting the production of eco-friendly
products demanded by customers. The results of our study support the case for the implementation of both lean prac-
tices and green practices. While the implementation of lean practices without green practices will result in significantly
improved operational performance, the impact of lean practices on environmental performance is slight. Combining lean
practices and green practices significantly improves environmental performance while also boosting operational perfor-
mance incrementally, notably consistent with complementarity theory.
Manufacturing managers striving to improve both the economic sustainability and environmental sustainability of
their firms should follow the implementation of lean manufacturing practices with the implementation of green supply
chain practices. Lean and green combine (1) to improve operational performance through the elimination of wastes
thereby reducing costs and enhancing economic sustainability, (2) to improve environmental performance through the
elimination of environmental wastes in particular thereby, enhancing the environmental sustainability of the firm, thereby,
providing the firm with possibly unique resources (resource heterogeneity) that are not readily or easily obtainable (im-
perfectly mobile) as is consistent with synergies related to complementarity theory and (3) to improve operational perfor-
mance from complementarity or the synergy produced by the full integration of lean practices and green practices.
Disclosure statement
No potential conflict of interest was reported by the authors.
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16 R.A. Inman and K.W. Green
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Appendix1. (Continued )