Real-time energy flow mapping: A VSM-based proposal for energy efficiency

Abstract

Rising energy costs and the current concern about sustainability issues directly impact the competitiveness and survival of organizations, promoting the search for continuous improvement in industrial production processes. The present study, by identifying the absence in the literature of models based on Value Stream Mapping and integrated with Industry 4.0 technologies that promote better energy efficiency practices in industrial processes, proposes a new Lean Management model called Real-time Energy Flow Mapping. This innovative model, provide capabilities to a visual, digital and sustainable management system of all energy behavior in machines and equipment using fully parameterizable metrics and rules. Also, estimulating stakeholders with the ability to predict and monitor energy costs, as well as identify possible problems due to changes in the behavior of energy consumption in machines, thus helping managers to make decisions faster and more dynamically. As a result, the literature search turned up 17 Value Stream Mapping based models with a focus on energy efficiency, along with 31 metrics grouped on energy, environmental and production processes. After discussions by the Focus Groups, 16 resulting metrics were submitted to expert panel, in which the least relevant were discarded and the 13 most relevant classified using Fuzzy Delphi. An analysis to verify the interrelationships between the metrics is performed using the Fuzzy DEMATEL, being finally applied in the proposed model. A case study of the model was carried out, submitting it operationally at the LabFaber 4.0, empirically validating the study. The Real Time Energy Flow Map fills the gap in the literature on Value Stream Mapping models to improve energy efficiency, monitoring energy consumption through dynamic mapping of the energy flow of production processes, identifying the area with increased potential for energy savings through changes in operating behavior that reduce overall energy consumption and environmental impacts.