Design and Implementation of Scalable Lean Robotics for Sustainable Production in Small and Medium-Sized Enterprises

Small and medium-sized enterprises (SMEs) are expected to contribute to sustainable manufacturing, yet they often lack the resources and capabilities needed to adopt advanced automation in a structured and scalable manner. While lean robotics have been widely studied, there is still limited empirical evidence on how their integration can be systematically designed to improve sustainability-oriented performance in SME contexts. This paper examines how a scalable lean robotics system can be conceived and implemented to enhance productivity and resource efficiency in an SME packaging process. We develop a lean robotics design approach that jointly considers lean principles, collaborative industrial robotics, and Industrial Internet of Things (IIoT) monitoring. The approach is applied in a real-world case study of a “Fold Station” robotic cell, where stone paper sheets are destacked, glued, and formed into cylindrical plant protectors. Key performance indicators related to cycle time, material utilization, process stability, and manual workload are measured before and after implementation. The results show a three- to four-fold reduction in preparation time per unit, more efficient use of stone paper and adhesive, and a decrease in repetitive manual handling, thereby contributing to both economic and environmental sustainability. TRIZ (Teoriya Resheniya Izobretatelskikh Zadach, Theory of Inventive Problem Solving) is used to structure the resolution of design contradictions that arise when embedding lean principles into the robotic system and to support its scalable adaptation to different production scenarios. This study advances the understanding of lean robotics for sustainable SME production and derives practical guidelines for designing scalable, resource-efficient robotic cells.