CO2lean

CO2lean is a research‑driven initiative that integrates carbon‑footprint accounting with lean manufacturing principles to help industrial organizations reduce greenhouse‑gas emissions while maintaining operational efficiency. Launched in 2021 through a collaboration of European universities, technology firms, and several mid‑size manufacturers, the project aims to provide a standardized methodology for quantifying CO₂ emissions at each stage of a production system and to identify lean‐based improvement opportunities that lower both waste and carbon output.

The framework combines life‑cycle assessment (LCA) tools with value‑stream mapping, enabling users to trace emissions linked to material handling, energy consumption, and process inefficiencies. CO2lean’s methodology is structured around five core steps: baseline assessment, emission hotspot identification, lean analysis of waste (overproduction, waiting, transport, excess inventory, motion, defects, and over‑processing), implementation of targeted lean interventions, and continuous monitoring through digital dashboards. Results from pilot studies in the automotive, food‑processing, and electronics sectors have reported average emission reductions of 12–18 % alongside cost savings of 5–9 % per annum.

The initiative also provides open‑source software tools and training modules, encouraging wider adoption across small and medium‑sized enterprises (SMEs). Funding for CO2lean is sourced from the European Union’s Horizon Europe programme and national research grants, supporting ongoing development of sector‑specific guidelines and integration with emerging Industry 4.0 technologies. By aligning environmental stewardship with lean operational excellence, CO2lean seeks to promote sustainable competitiveness in European manufacturing.