Integration of Sustainable Value Stream Mapping (Sus. VSM) and Life-Cycle Assessment (LCA) to Improve Sustainability Performance

Abstract

Sustainable manufacturing concept is adopted by many stakeholders for its framework, on considering environmental, social, and economic aspect, called as triple-bottom-line (TBL). It concerns the future of manufacturing review on sustainability and requires deeper evaluation on TBL and product life cycle as well as to see the environmental impact at process stage. In this work, a proposed Sustainable Value Stream Mapping (Sus-VSM) as an extended traditional VSM considers integration with Life-Cycle Assessment (LCA) to assess current condition in addition to analyze future sustainability improvement at a food based manufacturing. The current state presented all metrics associated with the TBL of manufacturing metrics. Calculation of critical metrics using the Borda Count Method (BCM) showed that speed-loss, total defect product, and heat loss were critical and chosen for further analysis. Analysis using 5 Whys analysis showed that the problems were mainly caused by the unstable material condition, the problem of filling area machinery, and operator disciplinary. Process life-cycle assessment was performed using Simapro v. 8.0 with single score cooking and cleaning. It obtained 60 700 Pt and 108 Pt. Future improvement using Failure Mode and Effect Analysis (FMEA) proposed and could reduce lead time from 4967.46 seconds to 4759.17 seconds, cleaning time from 2.8 hours to 2.14 hours, and total defect product from 4.85/batch to 2.82 kg/batch. Future improvement on steam performance proposed and could reduce the total single score of cooking and cleaning to 59 500 Pt and 102 Pt.