MSM - Multi-Layer Stream Mapping as a Combined Approach for Industrial Processes Eco-efficiency Assessment

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Nowadays achieving sustainable development is a global concern. The issue of unsustainability can be related to population growth and excessive consumption of natural resources. To tackle these issues, several management tools and methodologies have been developed in the last years, to assess, analyse and improve the environmental and economic performance of production systems. This work presents an approach based value stream mapping in order to assess and improve energy efficiency, environmental performance and financial performance of a production system. The developed approach can be applied to any industry or production system, where all the unit processes involved are identified and the inputs/outputs of each unit system quantified and easily perceived. Key environmental performance indicators and the corresponding eco efficiency ratios arise as outcomes of this approach, in which a Multi Layer Stream Mapping (MSM) with visual management attributes is created

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MSM - Multi-Layer Stream Mapping as a Combined Approach for Industrial Processes Eco-efficiency Assessment

  1. 1. 1PRODU[T]ECHAUTOMOBILE AND TRANSPORTAERONAUTICS, SPACE AND DEFENCEHEALTHSEA ECONOMYENERGYEQUIPMENT AND DURABLE GOODSSERVICESENVIRONMENTMulti-Layer Stream Mapping as a CombinedApproach for Industrial ProcessesEco-efficiency AssessmentE.J. Lourenço1, A.J. Baptista1, J.P. Pereira1, and Celia Dias-Ferreira21 INEGI - Institute of Mechanical Engineering and Industrial Management,Campus FEUP, Universidade do Porto, Porto, PORTUGAL2 CERNAS - Research Center for Natural Resources, Environment and Society,Campus da Escola Superior Agrária, Coimbra, PORTUGALSingapore 17-19 April 2013
  2. 2. 2PRODU[T]ECHMulti-Layer Stream Mapping as a Combined Approachfor Industrial Processes Eco-efficiency AssessmentCIRP – LCE 2013 Singapore, 17-19 April 2013CONTENTS1. Introduction2. Value Stream Mapping: The root for the concept3. The Multi-layer Stream Mapping Description4. Strengths of the MSM concept and applicability5. Application Example6. Conclusions and Future Work
  3. 3. 3PRODU[T]ECHMulti-Layer Stream Mapping as a Combined Approachfor Industrial Processes Eco-efficiency Assessment1. IntroductionCIRP – LCE 2013 Singapore, 17-19 April 2013Eco-efficiencyLast decades economic growth and industrialization lead to major environmental impactsIn the 90’s the World Business Council for Sustainable Development (WBCSD) defined the termeco-efficiency, which combines ecological and economical efficiencyWBCSD developed a framework to assesses eco-efficiency in order to promote sustainabledevelopment. The main goals are: maximize value creation (more goods/services) and minimizeenvironmental burdens (less resource consumption and waste creation)Eco-efficiency measures the relationship between economic growth and environmentalpressure, and is generally expressed by the ratio between economic value and environmentalinfluence, represented by.Eco-efficiencyProduct or service valueEnvironmental Influence
  4. 4. 4PRODU[T]ECHMulti-Layer Stream Mapping as a Combined Approachfor Industrial Processes Eco-efficiency Assessment1. IntroductionCIRP – LCE 2013 Singapore, 17-19 April 2013Eco-efficiencyEco-efficiency as a management philosophy towards sustainability can be a very useful tool toassess environmental and economic performance and enhance the global performance of acompany or even of a production systemThe framework developed by WBCSD can be used by any business to assess and measureprogress towards economic and environmental sustainability.However, this framework lacks a simple and discrete approach in order to analyze and assessunit processes that are part of a production system
  5. 5. 5PRODU[T]ECHMulti-Layer Stream Mapping as a Combined Approachfor Industrial Processes Eco-efficiency Assessment1. IntroductionCIRP – LCE 2013 Singapore, 17-19 April 2013ObjectivesDevelop a multi-variable combined use of the Value Stream Mapping (VSM) Lean Tool anddemonstrate its suitability to assess environmental and energy performance of unitprocesses and production systems in a fast and flexible manner. This by mapping the unitprocesses inputs and outputs and assessing their efficiency.Demonstrate the importance of presenting environmental issues and eco-efficiencyperformance in a simple manner through visual management maps and layouts, in order tosimplify top/middle management understanding of the Key Environmental PerformanceIndicators (KEPI’s) and their suitability for decision making and overall awareness.Create an approach that solves the existing eco-efficiency tools and methods that are notalways directly applicable to every product and/or production system, and often addressedas “isolated stage analysis”.Create a very easily understandable assessment (for all level collaborators) based in fastvisual management attributes in most methods and tools used for eco-efficiencyassessments.
  6. 6. 6PRODU[T]ECHMulti-Layer Stream Mapping as a Combined Approachfor Industrial Processes Eco-efficiency Assessment2. Value Stream Mapping: The root for the conceptCIRP – LCE 2013 Singapore, 17-19 April 2013Value Added vs NON Value AddedA value stream mapping consists basically in the collection of all actions (actions that addvalue and actions that do not add value) that are required to bring a product or a group ofproducts through the main flow, starting with the customer and ending with the raw-material (upstream).The primary goal of this tool is to identify all types of waste in the value stream flow andprocesses in order to take actions to try and eliminate these, by analyzing the Value StreamMap.Example of a common VSM of a Metalworking IndustryTransportWTS(input)CleaningWTSCoating boltholes(manually)Mixing paint(pneumaticmixer)Applyingprimer coatDryingprimarycoatCoatingInspection2 2 2 2 2 2 2VA 0,75 h 0,50 h 0,50 h 1,50 h 3,00 h 0,50 h PT 6,75 hNVA LT 7,89 h0,38 h 0,03 h 0,20 h 0,15 h 0,15 h 0,06 h WT 1,14 h86%0,70 h0,53 h1,13 h0,17 h- 66% 94% 71% 89%ProductionTime (hours)0,56 h3,15 h1,65 h0,17 h91% 95%
  7. 7. 7PRODU[T]ECHMulti-Layer Stream Mapping as a Combined Approachfor Industrial Processes Eco-efficiency Assessment2. Value Stream Mapping: The root for the conceptCIRP – LCE 2013 Singapore, 17-19 April 2013The MSM framework combines Value Stream Layers evaluated by the waste elimination /value creation mindset, identifying the variable part that adds value from the one that doesnot add value, with detailed unit process inventory and visual management attributesThe VSM root transforms, in the MSM concept, the understanding of eco-efficiency intosomething easily quantifiable, simpler, concise and directly applicable to any productionsystem, in a process sequence or even in compartmented unitsTo assess the environmental, financial and global performance of a production system (by thecomposition analysis of its subparts), and identifying and quantifying the inefficiencies ormisuses, the MSM concept starts from the classic bathtub curve of Value Stream MappingThe combined use of Value Stream Layers of a Value Stream Map emerges in order to “seebeyond” the global environmental and financial performance of a production system in asimpler manner and enable the understanding of the eco-efficiency assessments, and at thesame time simplify the identification and quantification of specific inefficiency situations
  8. 8. 8PRODU[T]ECHMulti-Layer Stream Mapping as a Combined Approachfor Industrial Processes Eco-efficiency Assessment3. The Multi-layer Stream Mapping DescriptionCIRP – LCE 2013 Singapore, 17-19 April 2013The MSM consists in replicating part of the approach used for Value Stream Mapping,but allowing the addition of multiple layers (stream flows for each process variable) thatembrace environmental and economic aspects, or other variable, to assess eco-efficiencyVSMMSMØTPi=PTPiLTPi[%]ØEPi=PEPiTEPi[%]ØCPi=PCPiTCPi[%]ØXPi=PXPiTXPi[%]
  9. 9. 9PRODU[T]ECHMulti-Layer Stream Mapping as a Combined Approachfor Industrial Processes Eco-efficiency Assessment3. The Multi-layer Stream Mapping DescriptionCIRP – LCE 2013 Singapore, 17-19 April 2013The values located below of the MSM line are those which do not add value to the product,i.e. representing the waste/misuses of time, money or resourcesThe values that are presented above the MSM line (Process Stages) are those that add valueto the product, thus representing the “useful consumption” of stream flow that can beanalyzed in order to assess, evaluate and quantify production efficiency and eco-efficiencyØTP1ØTPiØTP2ØEP1ØEPiØEP2ØCP1ØCPiØCP2ØXP1ØXPiØXP2
  10. 10. 10PRODU[T]ECHMulti-Layer Stream Mapping as a Combined Approachfor Industrial Processes Eco-efficiency Assessment3. The Multi-layer Stream Mapping DescriptionCIRP – LCE 2013 Singapore, 17-19 April 2013The MSM approach considers dimensionless ratios (actual variable divided by the maximumof the same variable, on the same process step), so the higher the result for the ratio, thebetter the performance of the energy, mass or time flow or other key variable of aprocess or systemThe process variables, must be assigned consistently to be maximized. The analysis ofvariables with the MSM is almost unlimited, for instance, the following environmental aspectscan take place as assessing variables:Electrical energyRaw MaterialFuelCO2 Emissions reductionWaste eliminationToxic materials reductionBeside environmental aspects, other specific cost flows can be added, i.e. cost flow lines toassess the costs of energy consumption only, or raw material only, thus allowing to assessspecific eco-efficiency indicators (since product value and environmental influence are specific)For a faster assess of the efficiency quantity, it was added visual management attributes byrelating a very common key of 4 colors (red, orange, yellow, green) in the positive direction ofefficiency, from 0% to 100%
  11. 11. 11PRODU[T]ECHMulti-Layer Stream Mapping as a Combined Approachfor Industrial Processes Eco-efficiency Assessment3. The Multi-layer Stream Mapping DescriptionCIRP – LCE 2013 Singapore, 17-19 April 2013MSM global efficiency dashboard (illustrative data)Process Stream AnalysisMulti-LayerStreamMappingProcess Efficiency 100 - 90%Process Efficiency 89 - 70%Process Efficiency 69 - 40%Process Efficiency <40%
  12. 12. 12PRODU[T]ECHMulti-Layer Stream Mapping as a Combined Approachfor Industrial Processes Eco-efficiency Assessment4. Strengths of the MSM concept and applicabilityCIRP – LCE 2013 Singapore, 17-19 April 2013MSM StrengthsThe MSM approach can assess, quantify and analyze environmental aspects (energyconsumption, emissions, raw material consumption etc.), economic aspects and productionsaspects one by one for each unit process. On the other hand the global performance can beassessed and quantified.One key feature of the MSM approach consists in considering dimensionless ratios, so thehigher the result for the ratio, the better the performance. This feature allows the comparisonof efficiency performance of distinct variables, and combine an integrated quantification of theoverall efficiency, for instance by weighted average or product (by column or row)The outcome and results are a diagrammatical and intuitive representation of managerialconcepts, and can be very practical and useful for:Top management decision supportDefining prioritiesIdentifying inefficiencies in an easy mannerIdentifying Key Environmental Performance Indicators (KEPI)Assessing eco-efficiency performanceIdentifying improvement actions needsInforming all level of collaborators of the efficiency of the production cell or unit
  13. 13. 13PRODU[T]ECHMulti-Layer Stream Mapping as a Combined Approachfor Industrial Processes Eco-efficiency Assessment4. Strengths of the MSM concept and applicabilityCIRP – LCE 2013 Singapore, 17-19 April 2013MSM StrengthsThis approach can also be used for process re-engineering evaluation (multi-scenarios analysis),since in some cases the unit processes, or even the whole production system of a factory, havegood operational results, but the efficiency is not as high as it could be.Therefore, using this approach to start point for scrutinize “where”, “how”, and “how much” cana unit process and/or a production system improve its financial, environmental and performanceaspects, is of great importance for decision-makingIt’s simplicity is one great advantage, since it allow a very fast and visual assess of multi-variableefficiency and its integration (for instance by heighted average), simultaneously for topmanagement or even workers.
  14. 14. 14PRODU[T]ECHMulti-Layer Stream Mapping as a Combined Approachfor Industrial Processes Eco-efficiency Assessment4. Strengths of the MSM concept and applicabilityCIRP – LCE 2013 Singapore, 17-19 April 2013(*) If the data inventory exists(*) If the data inventory exists(*) If the data inventory exists(*) If the data inventory exists… and …… and …… and …… and …LLLL1111 (line 1) = M(line 1) = M(line 1) = M(line 1) = M11111111 (machine 11) +(machine 11) +(machine 11) +(machine 11) + MMMM1i1i1i1i (machine(machine(machine(machine 1i) +…1i) +…1i) +…1i) +…LLLL2222 (line(line(line(line 2)2)2)2) ==== MMMM21212121 (machine(machine(machine(machine 21212121) +) +) +) + MMMM2i2i2i2i (machine 2i(machine 2i(machine 2i(machine 2i) +…) +…) +…) +…MSM drilldown (*)MSM drilldown (*)MSM drilldown (*)MSM drilldown (*)ProcessesProcessesProcessesProcessesLinesLinesLinesLines
  15. 15. 15PRODU[T]ECHMulti-Layer Stream Mapping as a Combined Approachfor Industrial Processes Eco-efficiency Assessment4. Strengths of the MSM concept and applicabilityCIRP – LCE 2013 Singapore, 17-19 April 2013Combine MSM analysis with mapping of layoutsCombine MSM analysis with mapping of layoutsCombine MSM analysis with mapping of layoutsCombine MSM analysis with mapping of layoutsP360%L161%L262%L357%
  16. 16. 16PRODU[T]ECHMulti-Layer Stream Mapping as a Combined Approachfor Industrial Processes Eco-efficiency Assessment4. Strengths of the MSM concept and applicabilityCIRP – LCE 2013 Singapore, 17-19 April 2013Integrate MSM results and layoutsIntegrate MSM results and layoutsIntegrate MSM results and layoutsIntegrate MSM results and layoutsP360%L1 L2L361% 62%57%P260%P190%P475%Company71%LinesPlant
  17. 17. 17PRODU[T]ECHMulti-Layer Stream Mapping as a Combined Approachfor Industrial Processes Eco-efficiency Assessment4. Strengths of the MSM concept and applicabilityCIRP – LCE 2013 Singapore, 17-19 April 2013Other MSM applicationsOther MSM applicationsOther MSM applicationsOther MSM applications Wine Vineyard FarmWine Vineyard FarmWine Vineyard FarmWine Vineyard FarmOther examples:Other examples:Other examples:Other examples:HospitalsHospitalsHospitalsHospitalsBuildingsBuildingsBuildingsBuildingsOffice units (Services or Engineering)Office units (Services or Engineering)Office units (Services or Engineering)Office units (Services or Engineering)Transport companiesTransport companiesTransport companiesTransport companiesetc…etc…etc…etc…BedBedBedBed 2222BedBedBedBed 3333BedBedBedBed 1111
  18. 18. 18PRODU[T]ECHMulti-Layer Stream Mapping as a Combined Approachfor Industrial Processes Eco-efficiency Assessment4. Strengths of the MSM concept and applicabilityCIRP – LCE 2013 Singapore, 17-19 April 2013MSM comparison regarding other performance indicatorsMSM comparison regarding other performance indicatorsMSM comparison regarding other performance indicatorsMSM comparison regarding other performance indicatorsThe visual management attributes integration and its mathematical simplicity, based on thewell-known VSM lean tool, the MSM can be viewed as a promoter for the importance ofassessing, evaluating and quantifying environmental aspects of an industrial process or plant,in order to improve global industrial performance
  19. 19. 19PRODU[T]ECHMulti-Layer Stream Mapping as a Combined Approachfor Industrial Processes Eco-efficiency Assessment5. Application ExampleCIRP – LCE 2013 Singapore, 17-19 April 2013MSM simplified diagramMSM simplified diagramMSM simplified diagramMSM simplified diagram
  20. 20. 20PRODU[T]ECHMulti-Layer Stream Mapping as a Combined Approachfor Industrial Processes Eco-efficiency Assessment6. Conclusions and Future WorkCIRP – LCE 2013 Singapore, 17-19 April 2013Develop a mathematical approach for optimization system purposesStudy the application of the results for Life Cycle Engineering decision support, assessingprocess/resource usage efficiency vs. process/resource usage eco-efficiencyStudy its application in multi-product analysisDevelop data base with environmental impact (single score contribution – Pt) for major/mostcommon materials and energy types/flowsConclusionsConclusionsConclusionsConclusionsFuture WorkFuture WorkFuture WorkFuture WorkMSM concept, based on the lean tool VSM, brings new perspective on how eco-efficiencyassessments results can be quantified by a discreet method for a process sequence or a individualsystemIt integrates strong visual management attributes and is mathematically simple (very easy to usefor all kind of stakeholders)Very versatile and wide range concept that can be applied for multi-variable and multipleeconomic activities (project management, logistics, economics, services, health care, etc.)
  21. 21. 21PRODU[T]ECHThank YouMulti-Layer Stream Mapping as a Combined Approach forIndustrial Processes Eco-efficiency AssessmentE.J. Lourenço, A.J. Baptista, J.P. Pereira, and Celia Dias-FerreiraCorresponding author: abaptista@inegi.up.ptINEGI - Institute of Mechanical Engineering and Industrial Management,Campus FEUP, Universidade do Porto, Porto, PORTUGAL

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