Therblig-embedded value stream mapping method for lean energy machining

To improve energy efficiency, extensive studies have focused on the cutting parameters optimization in the machining process. Actually, non-cutting activities (NCA) occur frequently during machining and this is a promising way to save energy through optimizing NCA without changing the cutting parameters. However, it is difficult for the existing methods to accurately determine and reduce the energy wastes (EW) in NCA. To fill this gap, a novel Therblig-embedded Value Stream Mapping (TVSM) method is proposed to improve the energy transparency and clearly show and reduce the EW in NCA. The Future-State-Map (FSM) of TVSM can be built by minimizing non-cutting activities and Therbligs. By implementing the FSM, time and energy efficiencies can be improved without decreasing the machining quality, which is consistent with the goal of lean energy machining. The method is validated by a machining case study, the results show that the total energy is reduced by 7.65%, and the time efficiency of the value-added activities is improved by 8.12% , and the energy efficiency of value-added activities and Therbligs are raised by 4.95% and 1.58%, respectively. This approach can be applied to reduce the EW of NCA, to support designers to design high energy efficiency machining processes during process planning

Industrial symbiosis implementation by leveraging on process efficiency methodologies

Resource efficiency is a crucial step for manufacturing companies to improve their operations performance and to reduce waste generation. However, there is no guarantee of a zero waste scenario and companies need to look for new strategies to complement their resource efficiency vision. Therefore, it is important to enroll in an industrial symbiosis strategy as a means to maximize industrial value capturing through the exchange of resources (waste, energy, water and by-products) between different processes and companies. Within this, it is crucial to quantify and characterize the waste, e.g. to have clear understanding of the potential industrial symbiosis hot spots among the processes. For such characterization, it is proposed to use an innovative process efficiency assessment approach. This empowers a clear understanding and quantification of efficiency that identifies industrial symbiosis hot spots (donors) in low efficiency process steps, and enables a plausible definition of potential cold spots (receivers), in order to promote the symbiotic exchanges

Waste reduction in production processes through simulation and VSM

Corporate managers often face the need to choose the optimal configurations of production processes to reduce waste. Research has shown that simulation is an effective tool among those conceived to support the manager's decisions. Nevertheless, the use of simulation at the company level remains limited due to the complexity in the design phase. In this context, the Value Stream Map (VSM)-a tool of the Lean philosophy-is here exploited as a link between the strategic needs of the management and the operational aspect of the simulation process in order to approach sustainability issues. The presented approach is divided into two main parts: a set of criteria for expanding the VSM are identified in order to increase the level of details of the represented processes; then, data categories required for the inputs and outputs of each sub-process modeling are defined, including environmental indicators. Specifically, an extended version of the classical VSM (X-VSM), conceived to support process simulation, is here proposed: the X-VSM is used to guide the design of the simulation so that the management decisions, in terms of waste reduction, can be easily evaluated. The proposal was validated on a production process of a large multinational manufacturing company

COMBINING SUSTAINABLE VALUE STREAM MAPPING AND SIMULATION TO ASSESS MANUFACTURING SUPPLY CHAIN NETWORK PERFORMANCE

Sustainable Value Stream Mapping (Sus-VSM) builds upon traditional VSM to capture additional sustainability aspects of the product flow, such as environmental and societal aspects. This work presents research to expand the utility of Sus-VSM to supply chain networks, develop a general approach towards improving supply chain sustainability, and examine the benefits of implementing simulation and a design of experiments (DOE) style analysis. Metrics are identified to assess economic, environmental, and societal sustainability for supply chain networks and visual symbols are developed for the Supply Chain Sus-VSM (SC Sus-VSM) to allow users to easily identify locations where sustainability can be improved. A discrete event simulation (DES) model is developed to simulate the supply chain, allowing easier creation of future state maps, which are used to identify locations for sustainability improvement. A scoring methodology and DOE-style analysis are developed to collect more information from the supply chain. Results from the case study show that the SC Sus-VSM meets the goals desired, and that the DES model aids the goals of the map. It is also indicated that interventions in the supply chain should first focus on economic improvements, followed by societal and then environmental improvements to achieve the greatest supply chain sustainability

Identifying and Eliminating Waste in a Coal Mining Industry: The Value Stream Mapping Analysis

Applying Value Stream Mapping (VSM) in the mining industry can increase productivity in production process activities. The coal mining industry has a vital role in life and is an essential investment in the regional economy. However, since 2017, coal production has experienced instability based on data from the Central Bureau of Statistics for East Kalimantan Province (2021) and has yet to meet consumer demand. Previous studies have only shed light on the critical theory that VSM has extended to many industries. However, those studies need to explain the concept of applying VSM to the mining industry. Therefore, to support this theory, a case study from the mining industry was conducted to determine cycle times and identify value-adding and non-value-adding activities. A current state map is developed after making the necessary observations and calculations. Different improvement proposals are identified, and a future state map for the industry is constructed. As a result, a 23.4% reduction in cycle time and 56.1% reduction in lead time ensure its applicability in the mining industry to increase productivity and meet customer demands. VSM is a powerful tool that helps mining managers and operators identify waste and opportunities for improvement. Efficiency is one of the most important things to consider in this industry. This study is especially true in the coal mining sector

Management tool design for eco-efficiency improvements in manufacturing - a case study

As the worldwide GDP is forecasted to double by 2035, the energy demand globally is expected to increase by 34%. The industrial sector is also expected to account for more than 30% of the primary energy demand by 2040. These projections make manufacturing operations even more complicated when combined with predicted long-term inflation of raw material prices and increasingly stringent environmental regulations. Therefore, it has become increasingly more challenging for practitioners in manufacturing to improve their eco-efficiency or to “do more with less”. Traditional manufacturing management tools based on lean principles such as Value Stream Mapping have not been designed to facilitate eco-efficiency improvements. On the other hand, environmental management tools such as Life-Cycle Analysis focus more on improving environmental impacts rather than financial sustainability. This paper addresses the design gap between these tools and proposes an integrated toolkit for eco-efficiency improvements. The toolkit development process and design principles are described through a case study in the flooring industry. Results from each module are validated and the overall output is used to propose a range of applicable solutions to the manufacturer. Paper presented at: Complex Systems Engineering and Development Proceedings of the 27th CIRP Design Conference Cranfield University, UK 10th – 12th May 2017

Green value stream mapping approach to improving productivity and environmental performance

[EN] Purpose The purpose of this paper is to introduce a new methodology called overall greenness performance for value stream mapping (OGP-VSM). Using value-added concepts, this approach has the potential to integrate, measure, control and improve productive and environmental performance in accordance with a company¿s context. Design/methodology/approach The OGP-VSM approach was developed by reviewing and integrating the environmental aspects of existing lean thinking tools and approaches. Findings This research revealed the lack of practical integration between productive and environmental performance. Using OGP-VSM, managers can see that environmental practices have a direct impact on productivity. OGP-VSM allows a balance to be found between lean and green practices in order to achieve the simultaneous improvement of productivity and environmental performance. Practical implications The proposed approach is applied to a case study in an automotive company in Spain and lays the groundwork for moving toward functional environmental sustainability in manufacturers. Originality/value Companies are increasingly implementing environmentally focused practices. Pursuing environmentally friendly (green) performance poses several challenges, but it also affords opportunities to create new methodologies for generating a competitive advantage for manufacturing companies. There are a limited number of approaches to drawing together the elements and attributes that are essential for a holistic, practical and long-lasting improvement of environmental performance in the manufacturing sectorThe work presented in this paper was carried out within the framework of the LIFE MCUBO research project funded by the European Union (LIFE15 ENV/ES/000379), through the LIFE programme. In addition, the authors would like to acknowledge the support received from AdP, the Special Patrimonial Fund at Universidad de La Sabana and the doctoral grant from TECNUN Escuela de Ingenieros, Universidad de Navarra.Muñoz-Villamizar, A.; Santos, J.; García Sabater, JJ.; Lleo, A.; Grau, P. (2019). Green value stream mapping approach to improving productivity and environmental performance. International Journal of Productivity and Performance Management. 68(3):608-625. https://doi.org/10.1108/IJPPM-06-2018-0216S608625683Diaz-Elsayed, N., Jondral, A., Greinacher, S., Dornfeld, D., & Lanza, G. (2013). Assessment of lean and green strategies by simulation of manufacturing systems in discrete production environments. CIRP Annals, 62(1), 475-478. doi:10.1016/j.cirp.2013.03.066Maroto-Sánchez, A. (2012). Productivity in the services sector: conventional and current explanations. 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Waste Elimination for Manufacturing Sustainability

AbstractThe continuous improvement in manufacturing using waste elimination has been recognized as one of the most important tasks of socially responsible organizations. The capability to eliminate waste can lead to attaining environmental gains. Waste in any organizations is ranging from non-value adding activities to workplace hazards which can further lead to customers, employees and organizations dissatisfaction as well as environmental destruction. In this paper, nine waste types have been identified. Waste identification tools have been revisited. A waste elimination framework has been suggested as an approach for sustainability in manufacturing environment. The framework contains three consecutive phases: waste documentation, waste analysis, and waste removal

Operational Practices of Lean Manufacturing: Potentiating Environmental Improvements

Purpose: The objective of this paper is to investigate how environmental improvements can be achieved through operational practices of Lean Manufacturing. Design/methodology/approach: A literature review was conducted to analyze the relationship between operational practices of Lean and reduction of environmental impact in organizational contexts. Verified theoretically, this relationship was observed in a company of the electronics industry, through an exploratory research which contemplated a mixed approach. The adopted research method consisted of a single case study, by providing greater depth and detail of the study. Utilized a research protocol, validated pilot test. The instruments for data collection were semi-structured interviews, direct observation and document analysis. The information was examined qualitatively considering the technique for content analysis. Findings: As a result of the study, it was found that there is evidence for the existence of relationship between the practices of Lean, for example, Kaizen, PDCA (plan, do, check, act), Ishikawa Diagram, Poka-Yoke, and Standardized Work, with the reduction of environmental impacts of an organization. This reduction was observed after application of these practices that resulted in the reduction of energy consumption and water consumption. These results were accounted for financially, contributing to a reduction of annual costs by about US$ 17,900. Originality/value: The study presents in detail, the application of operational practices of Lean Manufacturing, with an effective view to reducing the environmental impact and cost reduction. The literature review, a detailed description of the application process and financial results are important information that contributes to the scientific studies that address traditional operating practices and the search for better environmental performance.Peer Reviewe