Implementation of Lean Manufacturing for Defect Reduction and Sustainable Production in the Metal Casting Industry: A Systematic Literature Review and Bibliometric Analysis

¹ Faculty of Engineering, Universitas Sebelas Maret, Surakarta, Indonesia
² Faculty of Engineering, Universitas Mercu Buana, Jakarta, Indonesia

^* Corresponding author: This email address is being protected from spambots. You need JavaScript enabled to view it.

Abstract

The metal casting industry plays a vital role in the global manufacturing supply chain by supplying critical components for the automotive, construction, and machinery sectors. However, high product defect rates remain a persistent challenge, leading to increased production costs, material waste, and reduced operational efficiency. This study systematically reviews the implementation of Lean Manufacturing in reducing product defects in the metal casting industry while identifying research trends, key success factors, and existing research gaps. A Systematic Literature Review (SLR) based on PRISMA guidelines was conducted and complemented by bibliometric analysis. Data were collected from Scopus, Web of Science, ScienceDirect, and Google Scholar for the period 2010–2025. From an initial pool of 240 publications, 23 articles met the inclusion criteria and were analyzed through qualitative synthesis and bibliometric mapping. Thematic analysis and co-occurrence network visualization using VOSviewer were used to identify dominant research themes and conceptual relationships. The results show a growing research trend since 2015, with major contributions from India, China, and the United Kingdom. Among 12 empirical studies reporting quantitative outcomes, Lean implementation reduced defect rates by 20–60%. Common tools include Value Stream Mapping (VSM), 5S, Kaizen, and Failure Mode and Effects Analysis (FMEA). Overall, the findings confirm that Lean Manufacturing improves production efficiency, product quality, and resource utilization in the metal casting industry, supporting more sustainable manufacturing practices. Future studies should integrate Lean approaches with digital technologies and sustainability-oriented manufacturing strategies.