Adoption of Lean, Agile, Resilient, and Cleaner Production Strategies to Enhance the Effectiveness and Sustainability of Products and Production Processes

07.Jul.2025

​This research assesses the impacts of five cleaner production (CP) profiles of soap products and the overall equipment effectiveness (OEE) of liquid detergent production lines. A simulation model was built to depict the “As-Is” condition, and then the overall equipment effectiveness was calculated. Results showed high rejection rates and bottlenecks, resulting in long average cycle times and waiting times, as well as low production rates and machine utilization. Consequently, lean, agile, and resilient actions were utilized to enhance the OEE of the line’s processes. The improvement results showed that the bottle placement, filling, labeling, and taping processes were enhanced by 237%, 4.67%, 5.41%, and 26.02%, respectively. Moreover, the smallest percentages of availability, quality, and performance were 97.46%, 99.82%, and 81.56%, respectively, indicating a considerable enhancement in the performance of the line’s processes. Further, cleaner production assessment was performed on soap products to estimate environmental profile indices for raw material, energy, product, waste, and packaging. The estimated overall environmental index was 107.93, with liquid waste contributing the largest index value. Therefore, a proposal for a water treatment system was suggested and then assessed. In conclusion, lean, agile, and resilient actions were found to be effective in enhancing the OEE of production processes. Moreover, cleaner production provided valuable support to decision-makers in determining the appropriate actions for improving the OEE and environmental performance of the technological processes and products of detergent …​