More Sustainable Performances Through Lean Practices: A Case Study

Companies recognise lean practices to be a useful methodology for the reaching of more efficient performances in manufacturing processes. Moreover, there is growing attention by customers towards methods aiming at the improvement of the environmental sustainability. The method proposed in the current study aims at improving process performance and at evaluating the impact of operational advancements on environmental sustainability achievements. An application to a large manufacturing company producing steel caps for food and beverage packages was developed integrating the traditional Value Stream Mapping approach with indicators measuring environmental impact: Environmental Performance Indicator, CO2 emissions, electricity and methane consumption, and Overall Environmental Equipment Effectiveness. After having implemented Kaizen actions aiming at meliorating overall performances, improvements both regarding operational performance and environmental sustainability were detected.

[1]  Seiichi Nakajima,et al.  Introduction to TPM: total productive maintenance , 1988 .

[2]  Maurizio Bevilacqua,et al.  Total quality control through value stream mapping: a case study of small medium enterprises , 2014 .

[3]  William Faulkner,et al.  Sustainable Value Stream Mapping (Sus-VSM): methodology to visualize and assess manufacturing sustainability performance , 2014 .

[4]  Sri Hartini,et al.  Extended value stream mapping to enhance sustainability: A literature review , 2017 .

[5]  Maurizio Bevilacqua,et al.  Lean practices implementation and their relationships with operational responsiveness and company performance: an Italian study , 2017, Int. J. Prod. Res..

[6]  Jose Arturo Garza-Reyes,et al.  The impact of lean methods and tools on the operational performance of manufacturing organisations , 2014 .

[7]  Kim Hua Tan,et al.  Green and lean sustainable development path in China: Guanxi, practices and performance , 2018 .

[8]  F. Frank Chen,et al.  Lean and green: A current state view , 2010 .

[9]  Ruisheng Ng,et al.  Integrating and implementing Lean and Green practices based on proposition of Carbon-Value Efficiency metric , 2015 .

[10]  Maurizio Bevilacqua,et al.  Implementing lean information management: the case study of an automotive company , 2015 .

[11]  Rosario Domingo,et al.  Overall Environmental Equipment Effectiveness as a Metric of a Lean and Green Manufacturing System , 2015 .

[12]  Robert John Mason,et al.  Lean and Green Thinking - Doing More with Less , 2003 .

[13]  T. Bortolotti,et al.  Successful lean implementation: Organizational culture and soft lean practices , 2015 .

[14]  John R. Shook,et al.  Learning to See: Value Stream Mapping to Create Value and , 1998 .

[15]  Dimitrios Folinas,et al.  Greening the canned peach production , 2015 .

[16]  Peng Wu,et al.  A cross-sector review on the use of value stream mapping , 2017, Int. J. Prod. Res..

[17]  Michael J. Lenox,et al.  LEAN AND GREEN? AN EMPIRICAL EXAMINATION OF THE RELATIONSHIP BETWEEN LEAN PRODUCTION AND ENVIRONMENTAL PERFORMANCE , 2001 .

[18]  Qinghua Zhu,et al.  Green supply chain management in China: pressures, practices and performance , 2005 .

[19]  Dimitrios Folinas,et al.  Greening the agrifood supply chain with lean thinking practices , 2014 .

[20]  Fazleena Badurdeen,et al.  Sustainable value stream mapping (Sus-VSM) in different manufacturing system configurations: application case studies , 2014 .

[21]  Celia Dias-Ferreira,et al.  Multi-Layer Stream Mapping as a Combined Approach for Industrial Processes Eco-efficiency Assessment , 2013 .

[22]  C. Keskin,et al.  Value stream maps for industrial energy efficiency , 2012, 2012 Proceedings of PICMET '12: Technology Management for Emerging Technologies.

[23]  Xiaoyong Pan,et al.  A carbon emission analysis model for electronics manufacturing process based on value-stream mapping and sensitivity analysis , 2012, Int. J. Comput. Integr. Manuf..

[24]  Andrew Fearne,et al.  Sustainable Value Stream Mapping in the Food Industry , 2009 .

[25]  Christoph Herrmann,et al.  Economic and environmental value stream map (E2VSM) simulation for multi-product manufacturing systems , 2016 .

[26]  Björn Johansson,et al.  Framework and indicators for a Sustainable Manufacturing Mapping methodology , 2010, Proceedings of the 2010 Winter Simulation Conference.

[27]  Wilfried Sihn,et al.  An Approach to Integrate Parameters and Indicators of Sustainability Management into Value Stream Mapping , 2016 .

[28]  Suresh Garg,et al.  Value stream mapping: literature review and implications for Indian industry , 2011 .

[29]  Egon Müller,et al.  Dual Energy Signatures Enable Energy Value-Stream Mapping , 2013 .

[30]  Leon F. McGinnis,et al.  An economic and environmental framework for analyzing globally sourced auto parts packaging system , 2008 .

[31]  Mohammad Dadashzadeh,et al.  A Value Stream Approach For Greening The IT Department , 2012, BIOINFORMATICS 2012.

[32]  S. Vinodh,et al.  Life cycle assessment integrated value stream mapping framework to ensure sustainable manufacturing: a case study , 2015, Clean Technologies and Environmental Policy.

[33]  Laura Purvis,et al.  Integrating the environmental and social sustainability pillars into the lean and agile supply chain management paradigms: A literature review and future research directions , 2018 .