Optimizing Manufacturing Sector through Business Process Reengineering and Lean Integration: A B2Lean Methodology Approach

Hari Lal Bhaskar ()
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Hari Lal Bhaskar: Starex University

SN Operations Research Forum, 2025, vol. 6, issue 1, 1-22

Abstract: Abstract This study aims to explore the integration of Business Process Reengineering (BPR) with Lean methodologies to optimize manufacturing processes. The proposed B2Lean methodology seeks to enhance efficiency, reduce waste, and improve overall performance in the manufacturing sector by merging the strategic approach of BPR with the continuous improvement focus of Lean practices. A case study methodology is employed to assess the implementation of the B2Lean approach in a manufacturing organization. The study involves a comprehensive analysis of existing processes, followed by the design and application of the B2Lean framework. Quantitative data on process performance before and after implementation are analyzed to evaluate the effectiveness of the integration. The findings reveal that the B2Lean methodology significantly improves operational efficiency, reduces cycle times, and enhances product quality. The synergy between BPR’s radical process redesign and Lean’s waste minimization leads to sustainable improvements in the manufacturing sector. Key success factors and challenges encountered during the implementation are also identified. The research provides valuable insights for manufacturing managers seeking to optimize their processes through a hybrid approach. The B2Lean methodology offers a structured framework for achieving substantial improvements in process performance, making it a practical tool for organizations aiming to stay competitive in a dynamic market environment. The integration of BPR and Lean has the potential to appeal to a broad audience, including those interested in operations management, supply chain management, and organizational change. This study contributes to the existing literature by presenting a novel approach that integrates BPR and Lean methodologies. The B2Lean framework offers a unique perspective on process optimization, combining the strengths of both approaches to deliver superior outcomes in the manufacturing sector.

Keywords: Business Process Reengineering (BPR); Lean integration; B2Lean methodology; IT- enabler; Continuous improvement; Manufacturing process optimization; Manufacturing sector (search for similar items in EconPapers)
Date: 2025
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DOI: 10.1007/s43069-024-00399-5

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