Redesigning Lean for Sustainability: A Risk-Aware VSM Framework for Continuous Improvement in Manufacturing

Riana Puspita; Lee Chang Chuan; Tan Chan Sin

doi:10.58915/aset.v5i1.3218

Authors

Riana Puspita Universitas Medan Area, Indonesia
Lee Chang Chuan Universiti Malaysia Perlis
Tan Chan Sin Universiti Malaysia Perlis

DOI:

https://doi.org/10.58915/aset.v5i1.3218

Keywords:

Lean Sustainability, Monte Carlo Simulation, Risk-Aware VSM, Sustainable Manufacturing, Sus-Risk-VVSM

Abstract

Manufacturing systems face the dual imperative of achieving operational excellence while meeting stringent sustainability and resilience goals. Traditional Lean and Value Stream Mapping (VSM) approaches, however, often lack structured risk management and fail to account for the impact of process variability on holistic sustainability performance. This study proposes and validates a novel Sustainability–Risk–Variability Value Stream Mapping (Sus-Risk-VVSM) framework, designed to bridge this gap. The framework systematically integrates the ISO 31000 risk management cycle and Triple Bottom Line (TBL) metrics into the Lean Six Sigma DMAIC structure. Validation involved a two-round Delphi study with industry and academic experts, confirming the clarity and relevance of the findings. A Monte Carlo simulation of a discrete manufacturing process demonstrated the framework’s superior performance, reducing process variability by 26%, lowering operational risk exposure by 35%, and improving a composite Sustainability Index by 30.2% compared to conventional VSM. Statistical analysis identified process variability (r = -0.71) and defect rate (r = -0.73) as the strongest predictors of sustainability outcomes. The study contributes a validated, integrated model that transforms Lean into a proactive, risk-aware tool for sustainable decision-making, supporting the transition to resilient, sustainable Industry 4.0 operations.

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