An energy mapping methodology to reduce energy consumption in manufacturing operations

Cosgrove, John; Duarte, Maria-Jose Rivas; Littlewood, John; Wilgeroth, Paul

doi:10.1177/0954405416673101

Cited by 22 publications

(9 citation statements)

References 18 publications

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“…Energy consumption is another improvement area identified in the ENP process. To apprehend how electricity is distributed throughout the process and to determine the equipment or areas with higher energy consumption, there is a need to develop the energy mapping flow as recommended by Cosgrove et al (2018). In this study, the energy mapping flow for the current‐state E‐VSM is provided in Figure A1, whereas the electricity is dispersed across the whole process.…”

Section: Implementing the Application: Results And Discussionmentioning

confidence: 99%

The application of Green Lean Six Sigma

et al. 2021

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Green Lean Six Sigma has been recently clarified to improve the environmental sustainability performance of operations, but it seems glaringly scarce and in need of cutting-edge studies to integrate the concepts of green, lean, and Six Sigma into one unified application. This paper is accordingly aimed at constituting the application of Green Lean Six Sigma as a cleaner production. In doing so, a Define, Measure, Analyze, Improve, and Control (DMAIC)-based approach that is one of Six Sigma's well-known methods was proposed to systematize a Green Lean tool-environmental value stream mapping. Thus, this paper as one of the preliminary studies aligns environmental value stream mapping with DMAIC through presenting the proposed methodological approach, which relies on the five DMAIC phases-Define, Measure, Analyze, Improve, and Control-and considers green wastes in each phase simultaneously. To support the narrow body of knowledge, this proposed approach was validated via the action research-oriented case study implemented in the substrate manufacturing system that seeks to develop the environmental sustainability of its production processes and subsequently its general competitiveness. The findings indicated the effectiveness of a DMAIC-based approach in systematizing environmental value stream mapping and improving its efficacy to achieve environmental sustainability. The case analysis revealed that the application can significantly lessen the consumption of chemicals and energy in the system by 28% and 21%, respectively.

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Section: Implementing the Application: Results And Discussionmentioning

confidence: 99%

The application of Green Lean Six Sigma

et al. 2021

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“…Energy flows must be outlined in the VSM to illustrate the flow and relationship of the energy generated from the source to the output. Cosgrove, Rivas Duarte, Littlewood, and Wilgeroth (2018) highlighted the energy flow through the VSM and successfully identified energy reduction opportunities. Energy consumption is selected as an environmental metric due to its direct relation to environmental sustainability, i.e.…”

Section: Environmental Metricsmentioning

confidence: 99%

DMAIC-based approach to sustainable value stream mapping: towards a sustainable manufacturing system

Jamil

Gholami

Saman

et al. 2020

Economic Research-Ekonomska Istraživanja

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The research for this article was built upon the discussion concerning sustainable value stream mapping (Sus-VSM), which had recently emerged towards advancing sustainable manufacturing systems. Research on this sustainable-oriented lean tool has been confined to only a handful of studies only. Specifically, the lack of a continuous improvement process, where subsequent value stream developmental maps can be established to continue the cycle, is highlighted as a notable shortfall of this application. To fill the gap, this paper proposes a methodological approach, based on the DMAIC improvement cycle, to systematically implement and conduct Sus-VSM studies. The proposed methodology is practically validated with an industrial case to support this narrow body of knowledge. The research findings revealed that a DMAIC-based approach can be effectively applied to systematize the Sus-VSM towards sustainable manufacturing. The paper also provides a guiding reference for operations managers who wish to undertake similar improvement projects and make their manufacturing operations more sustainable, and, hopefully, inspire other researchers and practitioners to broaden the study of this under-researched field, which is now receiving growing interest in various industries.

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“…As part of the procedure the energy use efficiency ratios are calculated to highlight hotspots for intervention. This definition of efficiency also lends itself naturally to use with the lean manufacturing concept of value stream mapping applied to resource efficiency (Litos et al 2017;Cosgrove et al 2018).…”

Section: Resource Use Efficiency Concepts and Manufacturing System Immentioning

confidence: 99%

A decision tool for improving manufacturing water usage efficiency

Sachidananda

Rahimifard

Webb

2020

International Journal of Computer Integrated Manufacturing

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The environmental drivers for improving the efficiency of water usage in manufacturing industry are strong. However, while a water reduction programme can initially produce worthwhile benefits with moderate effort, further significant reductions require change to product, process or operational planning. The investment risk represented by such changes may act as a disincentive for companies to proceed with water conservation efforts. To improve the situation a methodology and a supporting simulation tool for decision-making in water reduction investment is introduced in this work. The methodology is based on the concept of water usage efficiency introduced in previous work, which allows the identification of hotspots where the maximum gains from intervention can be achieved. The tool further supports a structured approach to ranking the feasibility and benefits of proposed interventions. A report is presented on application of the tool to the operations of a food-manufacturing company in India. The area with the greatest potential for improvement was identified as being water directly involved in the process of rice cooking, with the corresponding highest ranked intervention option being pre-soaking the rice. This option delivers the desired efficiency benefits while being lower cost than more technically involved interventions such as introducing water treatment equipment.

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An energy mapping methodology to reduce energy consumption in manufacturing operations

Cited by 22 publications

References 18 publications

The application of Green Lean Six Sigma

The application of Green Lean Six Sigma

DMAIC-based approach to sustainable value stream mapping: towards a sustainable manufacturing system

A decision tool for improving manufacturing water usage efficiency

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