This research addresses scrap optimization in the production of Aluminum Conductor Steel Reinforced (ACSR) overhead conductors using the stranding machine at a manufacturing facility in Bahrain. Although ACSR conductors are not commonly used locally due to underground wiring systems, Bahrain exports them widely, making efficient production essential. The study targets the reduction of wire leftovers caused by the inherent randomness in the stranding machine process, which contributes to high production costs and environmental concerns. To resolve this, the project employs a Monte Carlo simulation-based optimization strategy, supplemented by lean manufacturing principles, statistical process control, risk management, and financial analysis. The findings confirm that the applied approach significantly reduces scrap, enhances process reliability, and lowers operational costs. Additionally, it promotes more sustainable manufacturing by decreasing emissions and aligning with Bahrain’s 2060 net-zero goals. This initiative not only improves environmental outcomes—particularly air quality—but also boosts industrial efficiency, helping the company meet international environmental standards and attract global investment in sustainable practices. © The Author(s), under exclusive license to Springer Nature Switzerland AG 2026.