Blog Layout

You may be lean but are you green?

In today's evolving business landscape, the term "lean manufacturing" is commonplace. It is a pivotal concept celebrated for driving organisational success. A business model that prioritises activities customers are willing to pay for, while considering everything else as waste. Defined by its focus on managing and reducing waste, lean manufacturing seems, at least on paper, to address sustainability goals, but is lean enough?


What is lean manufacturing?

Emerging from the post-war 1950s through the Toyota Production System (TPS), lean manufacturing is built upon the concept of continuous and incremental improvements in both product and process. Its primary objectives are to reduce production time, improve responsiveness from suppliers and to customers, enhance product quality, and boost efficiency. This is achieved by eliminating, simplifying, reducing, or integrating activities that do not add value to the business, i.e. effectively managing and minimising waste.


Toyota identified 7 types of waste (Muda) in a business:


  1. Over production: producing products before a confirmed order.
  2. Unnecessary waiting: inactive work periods leading to lengthened cycle time which reduces agility and responsiveness.
  3. Unnecessary transportation: unnecessary movement of people and goods inside the system.
  4. Overprocessing: processes that are more complex than required or making parts beyond the standard expected by the customer.
  5. Unnecessary inventory: an excess of raw materials, work-in-process elements or finished products.
  6. Unnecessary motion: inefficient layout or automating processes before improving the method.
  7. Too many avoidable defects: poor quality output that needs correction.


A factory filled with lots of machinery and robots.

At its core, lean manufacturing embodies the relentless pursuit of efficiency and waste reduction across all facets of production. By eliminating unnecessary inventory, minimising lead times, and optimising workflows, businesses can achieve significant cost savings while boosting product quality and customer and employee satisfaction. Lean methodologies foster a culture of continuous improvement, empowering employees to identify and address inefficiencies proactively.


Key areas where lean business practices are commonly applied include:


  • Supply chain management
  • Production processes
  • Inventory control
  • Quality assurance
  • Workforce optimisation
  • Customer relationship management


Lean principles drive efficiency and promote agility, helping businesses to respond swiftly to changing market dynamics and customer demands. From small and medium sized businesses through to multinational corporations, the adoption of lean manufacturing methodologies has become synonymous with operational excellence and growth.



A silhouette of a factory made of grass on a white background.

How is green manufacturing different to lean manufacturing?

Green manufacturing (also known as sustainable or eco-friendly manufacturing) prioritises economically efficient procedures that also minimise the environmental impact of both the manufacturing process (using resources more efficiently, lowering energy consumption and reducing waste generation) and the complete life cycle of the product, from design through to disposal. It incorporates all the benefits of lean manufacturing, but with additional green credentials – highly attractive to customers, investors and current and future employees.


In short, the main distinction between green and lean manufacturing lies in their intent: green manufacturing strives to minimise the environmental impact, whereas lean manufacturing aims for maximum efficiency.


Embracing sustainable manufacturing

Green manufacturing embodies a holistic approach to production that prioritises environmental stewardship, social responsibility, and economic viability. It encompasses the integration of eco-friendly practices, renewable resources, and ethical labour standards to minimise ecological footprint and promote long-term sustainability.


Sustainable manufacturing initiatives vary from the straightforward and easily implementable measures to comprehensive and complex overhauls requiring industrial project management:


  • Encouraging employees to turn off equipment when it’s not being used.
  • Installing motion sensors to lights and self-closing taps in bathrooms.
  • Reusing materials currently discarded as waste.
  • Switching to renewable energy sources.
  • Using recycled/ recyclable materials in the manufacturing process.
  • Replacing equipment to more energy-efficient alternatives.
  • Procuring and installing specialist equipment to meet ongoing HSE and compliance requirements.
  • Reviewing the practical and economic implications of renewable thermal energy options to futureproof a business.



A globe is sitting on a wooden table next to a row of wooden blocks.

The benefits of transitioning towards sustainable manufacturing practices extend beyond environmental preservation; it's about creating shared value for stakeholders while safeguarding the planet for future generations. Integrating sustainability into core business strategies fosters innovation, drives competitive advantage, and breeds long-term resilience in an increasingly uncertain world. By embracing green business practices, businesses mitigate operational costs, enhance brand reputation, and capitalise on emerging market trends favouring sustainability.

Areas within an organisation ripe for green business practices include:



Bridging lean and green: the path to holistic optimisation

The comparison between lean and green manufacturing concepts also reveals their complementary nature and overlapping aspects:


  • Both emphasise resource productivity in manufacturing by reducing waste and emissions and promoting efficiency in production steps.
  • Employee involvement and training are vital for continuous improvement in both concepts.
  • Both require changed mindsets and company cultures supporting their underlying philosophies.


Integrating lean methodologies with sustainable manufacturing practices, enables organisations to unlock industry competitiveness and access new collaborations which amplify the environmental impact and drive meaningful change across the entire value-chain. 


An aerial view of a forest with the words `` deta '' written on it.

How can DETA help your business be lean and green?

The merging of lean and green principles represents a paradigm shift in contemporary business practices, surpassing traditional notions of efficiency and profitability. As businesses navigate the complexities of a rapidly changing world, embracing sustainability isn't just moral —it's a strategic imperative, and this is where DETA can help you.


DETA’s energy consultants in New Zealand and Australia play a pivotal role in business transformation. We appreciate the prospect of changing how your business operates can feel overwhelming, which is why we are with you every step of the way. Once we’ve identified and explored any inefficiencies in current working practices, we create and deliver a Sustainability Roadmap to pave the way for a more sustainable future—one that exploits the economic prosperity of lean manufacturing with the environmental stewardship and social equity of green manufacturing.


We look at your business holistically so we can implement the most effective energy-saving initiatives and develop comprehensive carbon reduction strategies tailored to your unique operational needs. We’re firm believers in making life as easy as possible for our clients, which is why we have an inhouse multidiscipline team of experts for both excellence and consistency.

Whether you require an energy audit and management, need advice from our wastewater consultants to ensure compliance with regulatory standards, or crave the guidance and invaluable insights from DETA’s sustainability consultants, you can unlock new opportunities for growth, resilience, and competitive advantage.



If you would like your business to be involved in positive change for a greener future, call DETA today, click here for contact details for our Aotearoa New Zealand, Australia, and the Pacific teams.

Proactive Solutions for New Zealand’s Gas Challenges

by Anne-Maree Ward • 13 December 2024
Energy Efficiency and Conservation: Navigating New Zealand's Gas Challenges New Zealand’s energy market is undergoing a dramatic transformation. Rising gas prices, a steady decline in local gas production, and the country’s ambitious decarbonisation targets are creating significant pressure for businesses to adapt. The era of cheap, reliable gas is fading, and for industries that rely on it, the time to act is now. Businesses need to move beyond merely coping with the changes and start embracing practical, forward-thinking solutions that drive efficiency, reduce costs, and align with New Zealand’s sustainability objectives. While the pressure to reduce fossil fuel dependency grows, there’s an opportunity for businesses to innovate. By adopting energy-efficient technologies and lower carbon alternatives, companies can gain a competitive edge while managing the immediate impacts of the gas crisis and preparing for a future with more sustainable energy sources. The evolving gas landscape: what’s driving the change? New Zealand’s gas sector is in a state of flux, with local production dwindling and no imported natural gas available. On top of this, the government’s commitment to achieving net-zero emissions by 2050 is placing additional pressure on businesses to reduce their carbon footprint. For many businesses, continuing to rely on gas is no longer a sustainable long-term strategy. Now is the time to take a step back and consider alternative energy solutions that provide greater stability and long-term value. The path forward involves shifting away from traditional fossil fuels, investing in energy-efficient technologies, and exploring lower carbon energy alternatives. Energy efficiency: the key to resilience While facing such uncertainty in the energy market, energy efficiency is more than just a cost-saving measure—it’s key to building resilience. By reducing energy consumption, businesses can mitigate the financial impact of rising gas prices, all while contributing to New Zealand’s decarbonisation goals. Achieving energy efficiency means not only cutting down on costs but it also positions businesses as leaders in sustainability, supports the uptake of a continuous improvement mindset across the business, and reduces environmental impact. But considering energy efficiency alone isn’t enough. The real challenge lies in the broader energy supply-demand balance across New Zealand. As businesses look to transition away from gas, the energy must still come from somewhere and the market has to react. This is a massive challenge for NZ Inc but many businesses are looking at ways to be innovative and creative with their energy usage and procurement utilising tools like storage, flexible operation and long term contracts to not only create maximise value for their organisations but also to support New Zealand's energy transition.

Measuring up: the importance of energy audits in business

12 December 2024
Historically, auditing has been seen as an undesirable expense with little perceived value for businesses. With organisations failing to see the benefit of examining the finer details of their operations, and with staff assigned to prepare for the audit feeling like they've drawn the short straw, audits have never been fun. Until now. This is when energy audits enter the room to great fanfare. The shift towards sustainability , driven by environmental, social, and governance (ESG) factors, is reshaping how businesses approach energy consumption, waste management, and carbon footprint, and crucially, their relationship with audits. Energy audits are the one type of audit that delivers positivity; they are one of the most effective tools to help businesses reduce their environmental impact while boosting their bottom line through optimised processes and reducing costs. For organisations across Aotearoa New Zealand, Australia, and the Pacific , understanding the significance of energy audits and how they lead to long-term cost savings, improved efficiency, and enhanced sustainability is fundamental to business success. Unpacking energy audits: the key to unlocking sustainability An energy audit is a comprehensive evaluation of a business's energy use and efficiency. Its primary goal is to uncover areas where energy is being wasted and identify opportunities for energy savings. This process is essential for any business aiming to improve its sustainability, reduce operating costs, and meet carbon reduction targets. Whether you are operating a small enterprise or managing a large industrial site, an energy audit provides actionable insights to reduce the environmental impact of the business and improve energy management. There are different types of energy audits, from Lite Audits offering a quick, low-risk assessment, to Detailed Energy Audits, which provide a more thorough and long-term analysis of energy use across the facilities. Both types of audits help you understand current energy consumption patterns and reveal the potential areas for energy efficiency improvements. From insight to action: why energy audits are a business game-changer Energy audits are not just about identifying problems; they are about identifying opportunities for improvement. By performing regular energy audits, businesses can benefit in the following ways: Cost savings One of the most immediate, attractive and tangible benefits of an energy audit is the potential for significant cost savings through the identification of inefficiencies that are costing the business or organisation money. For example, a company may be using outdated lighting or HVAC systems that consume excessive energy. Through equipment upgrades and optimisations , these inefficiencies can be corrected, leading to significant savings on utility bills. Energy audits are also adept at identifying unexpected bottlenecks in industrial processes and are often the first to highlight the potential for process optimisation, improving a business’s overall efficiency and profitability. 
Two construction workers are looking at a blueprint on a construction site.

From concept to completion: achieving industrial projects with sustainable agendas

12 December 2024
In today’s world, the intersection of industrial progress and sustainability has become a critical focus. As businesses and industries expand their reach, the importance of embedding sustainable practices into project management is no longer optional - it’s essential. By integrating sustainability principles from the early stages of a project through to completion, organisations can achieve not only economic gains but also valuable long-term environmental and societal benefits. The role of sustainability in industrial project management Sustainability in project management involves adopting practices that address environmental, social, and governance (ESG) considerations throughout the project lifecycle. This shift reflects a growing recognition that industrial success isn’t just about profitability; it’s about creating enduring value for communities and the ecosystems on which we rely. Industries across New Zealand and Australia are increasingly collaborating with sustainability consultants and ESG consultants to align their projects with global sustainability standards. These professionals guide organisations in setting and achieving ambitious goals, whether it’s reducing carbon footprints, improving resource efficiency, or enhancing social responsibility. For instance, energy consultants in NZ play a pivotal role in industrial projects by conducting energy audits and offering insights into energy-efficient designs, ultimately lowering operational costs and environmental impact. Key strategies for embedding sustainability in industrial projects Implementing sustainability isn’t just about compliance - it’s about innovation. Here’s how industrial project teams incorporate sustainability into their processes: 1. Defining clear sustainability goals Every successful project begins with a clear roadmap. Sustainability goals should align with both organisational values and broader environmental targets, such as the UN’s Sustainable Development Goals (SDGs). Collaborating with energy efficiency consultants and process engineering consultants helps businesses define measurable objectives, such as achieving specific reductions in energy consumption or waste. For example, organisations in the manufacturing sector can work with energy management services in NZ or Australia to develop energy audit services to pinpoint inefficiencies and identify greener alternatives. 
Show More
Share by: