Lean Six Sigma principles & “green culture” enhance circular manufacturing capabilities

Lean Six Sigma principles and “green culture” are crucial in enhancing circular manufacturing capabilities, a new research study has found. They foster a mindset shift toward sustainability and resource efficiency, ultimately driving the onset of the circular economy ecosystem, according to the study.

The researchers conducted a survey of 232 manufacturers and analyzed the collected data using the structural equation modeling approach.

The results have substantial implications for administrators looking to streamline their adoption of Lean six Sigma practices and cultivate a green culture to enhance their competitive advantage and boost their reputation.

Lean Six Sigma and green culture support circular manufacturing capabilities

It is evident that the pursuit of circular manufacturing capabilities by manufacturers significantly contributes to improving their plant, profit and people performance (3PP), which underscores the importance of adopting circularity principles in manufacturing operations to achieve environmental, economic and social benefits, the paper read.

Lean Six Sigma principles provide a structured framework for organizations to optimize their operations, reduce waste and improve efficiency, all of which are crucial to building circular manufacturing capabilities and driving meaningful progress toward more socially and environmentally friendly resource-efficient activities.

Lean Six Sigma also encourages the use of data-driven decision-making and knowledge sharing to facilitate continuous improvement within the manufacturing environment, the paper stated. 

Meanwhile, a strong green culture, which encompasses the principles and actions that give priority to environmental sustainability and responsibility within an organization, stimulates the development of circular manufacturing capabilities by instigating fundamental changes in the attitudes, actions and processes of businesses including their strategic partners across the manufacturing supply chain.

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The ongoing value of Lean Six Sigma

Despite being decades old, Lean Six Sigma is still widely recognized as one of the most effective methodologies for solving operational problems and driving continuous improvement. The PEX Report 2025/26 found that Lean is used by 40 percent of organizations to support business transformation, with 28 percent applying Six Sigma.

“Having spent two decades consulting with firms rolling out process improvement methodologies, I can say that Lean Six Sigma is not just surviving in 2025 – it’s flourishing,” said Nikhil Pal, operational excellence (OPEX) and digital transformation expert. “Lean Six Sigma addresses two fundamental business issues that never go away: minimizing waste and reducing variation. In fact, these requirements are more paramount (not less) in today’s digital age.”

The University of Kansas (KU) recently revived its in-person Lean Six Sigma Green Belt certification training. It is the first time it has been offered face-to-face since before 2020.

Meanwhile, Lean Six Sigma is enhancing combat readiness in the US Army. In the latest iteration of an ongoing partnership between the United States Military Academy West Point and Tobyhanna Army Depot (TYAD) – part of the US Army Communications-Electronics Command – three senior groups of cadets recently finished Lean Six Sigma Green Belt projects.

The initiative aims to educate cadets about tangible improvements in efficiency and operational readiness while providing them with invaluable exposure to real-world logistics challenges.

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