The research was based on a study at a domestic bicycle manufacturing company. The focus of the investigation was the question to what extent process improvement designed according to lean principles results in cost savings in the case of a switch to environmentally friendly packaging. The research describes the relationship between cycle time and takt time, and the role of continuous improvement. The article analyses the current packaging processes in the research site and the external reasons behind the changeover. Several layout and process versions were developed, and packaging materials were replaced with environmentally friendly alternatives. The research also studied in detail the standardization linked to the improvements. The final process was compared with previous conditions using back-testing data. The analysis included a multi-directional approach to economic benefit evaluation, which led to conclusions on the cost-effectiveness and operational benefits of the interventions.