Energy Consumption Optimization Based on Six-Sigma Tool (DAMIC) and Energy Value Stream Mapping

Abstract

The need of the hour is sustainability. In this research work, the integration of lean, green, and six-sigma methodologies is suggested. In order to classify the waste of energy as non-value activities in a process, the Lean Value Stream Mapper tool is amended to map the energy value stream. An energy-based model is developed to assess the maximum refusal or workplace rework. From all the data collected, a new value stream mapping called LESSVSM (Lean- Energy-Six Sigma value stream mapping) is being developed to identify the total energy consumption and wastage in value-added processes. The output is used to develop CTQ for the six-sigma project. With Lean and Six-Sigma methods, this rise in energy use can be tackled. Lean and Six Sigma are two principles that share the same methodologies and the same instruments, but in many ways, they are distinct. Six Sigma focuses on waste management and cost savings. Lean management is based on eliminating defects and reducing confusion. Six Sigma enhances process performance by identifying and removing the causes of the defect and reducing the variability of production processes. It mostly uses methods for analytical, statistical, and quality management and creates a special ecosystem of experts within the enterprise in these methods. A well-defined sequence of steps follows each Six-Sigma project undertaken in an organisation, which has a clear value goal: for example, minimising time, waste, expenditures, and client satisfaction as well as profitability, for example. Nevertheless, the implementation of Industry 4.0 and sustainable development objectives enhance environmental protection in order to achieve more positive and more environmentally effective funding than ever.