Increasing energy productivity in lean production system with energy oriented value-stream mapping

Abstract

Nowadays, reduction of energy waste becomes a great concern for manufacturing companies. They have to be energy efficient since it provides great saving potential. Hence, this research investigates the energy productivity in an auto body paint shop of an automobile manufacturer. In this study, energy wastages are detected by using the energy value-stream mapping (EVSM) approach based on lean production system. Then, a group of improvement plans are proposed and are evaluated by using a questionnaire which is filed by a group of specialists. Afterward, the proposed plans are assessed by using statistical analysis. Finally, improvement plans are determined by using an integer programming and a goal programming under two scenarios with regard to some defined constraints by the studied company. Furthermore, a sensitivity analysis is conducted to assess the effect of factors on the objective function and the number of improvement plans.