Operational excellence: beyond Lean
Operational excellence aims to continuously optimize processes to improve overall company performance. Traditionally focused on productivity and quality, it must now integrate the carbon dimension.
The decarbonization-performance convergence
Aligned objectives
Contrary to popular belief, operational excellence and decarbonization pursue similar objectives:
- Waste elimination: Less waste = fewer emissions
- Energy optimization: Efficiency = savings + CO₂ reduction
- Continuous improvement: Culture of permanent progress
Measurable gains
Companies that combine both approaches observe:
- 15-30% reduction in energy costs
- 20-40% reduction in GHG emissions
- Productivity improvement of 10-25%
Our integrated methodology
1. Combined diagnosis
We conduct a 360° diagnosis:
- Flow mapping (material, energy, information)
- Value-added analysis
- Detailed carbon footprint (Scope 1, 2, 3)
- Identification of losses and waste
2. Carbon ROI prioritization
We prioritize actions according to their:
- Carbon impact (tonnes of CO₂ avoided)
- Return on investment (payback period)
- Ease of implementation (required resources)
3. Agile implementation
Iterative approach in sprints:
- Quick wins (0-3 months): Immediate actions
- Medium-term projects (3-12 months): Moderate investments
- Transformations (1-3 years): Structural changes
4. Data-driven management
Integrated dashboards combining:
- Operational performance indicators (OEE, TRS)
- Carbon indicators (tCO₂e/unit produced)
- Economic indicators (costs, margins)
Use case: Luxury industry
A partner luxury house succeeded in:
- Reducing its emissions by 35% in 2 years
- Decreasing its energy costs by 28%
- Improving its OEE (Overall Equipment Effectiveness) by 18%
"Greendoy's combined approach allowed us to create a virtuous circle: each operational improvement reduced our emissions, and each low-carbon action improved our performance."
Operations Director, French luxury house
Low-carbon excellence tools
Carbon Value Stream Mapping
Extension of traditional VSM integrating:
- CO₂ emissions at each stage
- Energy consumption
- Carbon waste (waiting, inventory, unnecessary transport)
Carbon Kaizen
Continuous improvement sessions focused on:
- Reducing energy consumption
- Optimizing production cycles
- Eliminating material losses
5S + 1 (Safety + Sobriety)
The traditional 5S augmented with a 6th S:
- Sobriety: Reducing carbon footprint at each workstation
Concrete benefits
Operational
- Simplified and efficient processes
- Reduced cycle times
- Improved quality
Economic
- Lower energy costs
- Reduced waste and rejects
- Anticipation of carbon taxes
Environmental
- Reduced GHG emissions
- Decreased environmental footprint
- Contribution to Net Zero goals
Human
- Team engagement
- Pride of belonging
- Skills development
Conclusion
Operational excellence and decarbonization are not two separate projects but two facets of the same transformation. By combining them, companies create a sustainable competitive advantage.
Get started
Do you want to combine operational performance and decarbonization?
Contact us for a free diagnosis of your improvement opportunities.
