Driving Green Through Lean: A Structured Causal Analysis of Lean Practices in Automotive Sustainability

The urgent global challenge of environmental sustainability has intensified interest in integrating Lean Management practices with environmental objectives, particularly within the automotive industry, a sector known for both innovation and high environmental impact. This study investigates the systemic relationships between 16 lean practices and three environmental performance metrics: energy consumption, CO₂ emissions, and waste generation. Using the Fuzzy Decision-Making Trial And Evaluation Laboratory (DEMATEL) methodology, data were collected from seven lean experts in the Italian automotive industry to model the cause–effect dynamics among the selected practices. The analysis revealed that certain practices, such as Total Productive Maintenance (TPM), just-in-time (JIT), and one-piece-flow, consistently act as influential drivers across all environmental objectives. Conversely, practices like Statistical Process Control (SPC) and Total Quality Management (TQM) were identified as highly dependent, delivering full benefits only when preceded by foundational practices. The results suggest a strategic three-step implementation roadmap tailored to each environmental goal, providing decision-makers with actionable guidance for sustainable transformation. This study contributes to the literature by offering a structured perspective on lean and environmental sustainability in the context of the automotive sector in Italy. The research is supported by a data-driven method to prioritize practices based on their systemic influence and contextual effectiveness.