From People to Performance: Leveraging Soft Lean Practices for Environmental Sustainability in Large-Scale Production

Lean manufacturing can be considered a socio-technical system integrating both technical tools and human-centered, or soft, practices. While extensive research has examined technical aspects, the contribution of soft Lean practices focused on human behavior to environmental sustainability remains underexplored. This study addresses this gap by examining how soft Lean practices can help overcome barriers to environmental performance in large-scale production systems (LSPSs), using Italy’s food manufacturing sector as a case study. A multi-case study methodology was employed, involving five companies. Data were collected through interviews conducted across top management, middle management, and operational staff levels to capture diverse perspectives. Using variables extracted from the literature and a deductive coding approach, the study identifies (1) the specific soft Lean practices adopted and the perceived environmental performance barriers at each hierarchical level, (2) differences in interpretation of these practices and barriers across hierarchical levels, and (3) how soft practices can mitigate obstacles to sustainable performance. The results demonstrate that soft Lean practices, when aligned with organizational structure and culture, can effectively mitigate barriers to environmental improvement. This research contributes to the Lean and sustainability literature by offering a multi-level perspective and practical insights into integrating human-centered approaches within industrial sustainability strategies.