Skip to main content
main-content
Top

Hint

Swipe to navigate through the articles of this issue

Published in: International Journal on Interactive Design and Manufacturing (IJIDeM) 2-3/2021

26-07-2021 | Original Paper

An interactive resource value mapping tool to support the reduction of inefficiencies in smart manufacturing processes

Authors: Marco Marconi, Roberto Menghi, Alessandra Papetti, Giorgia Pietroni, Michele Germani

Published in: International Journal on Interactive Design and Manufacturing (IJIDeM) | Issue 2-3/2021

Login to get access
share
SHARE

Abstract

As nearly one third of global energy demand and CO2 emissions are attributable to manufacturing activities, the reduction of energy/resource consumption in the industrial sector is increasingly crucial. Therefore, research and innovation for the factories of the future is not only a matter of developing and integrating new technologies, but also a challenge to make manufacturing less dependent on energy and managed in an optimized way. This requires considering the efficiency of resource exploitation according to a systematic approach. To this aim, the present paper proposes a resource-saving tool, called Resource Value Mapping (RVM), and describes its application in a smart multinational company that produces electromechanical components for the automotive industry. The RVM tool is composed by three main modules that jointly allow the involved stakeholders to collaborate toward the optimization of the plant management: the Cloud data center that represents the repository of the collected real-time and offline data, the Analytics module that is responsible for data elaboration with the aim of calculating a set of key performance indicators useful to identify process inefficiencies, and the Web-based platform that represents the user interface of the tool. The case study demonstrated how such a tool allows (1) mapping the energy/resource flows to multiple levels (machine, line, plant), (2) characterizing them to identify the most critical activities that do not generate value and (3) supporting multiple stakeholders (plant manager, energy manger, operators) in the management of resource anomalies and definition of a more sustainable action plan.
Literature
1.
go back to reference World Commission on Environment and Development (WCED). Report of the World Commission on Environment and Development: Our Common Future (1987) World Commission on Environment and Development (WCED). Report of the World Commission on Environment and Development: Our Common Future (1987)
2.
go back to reference Bey, N., Hauschild, M.Z., McAloone, T.C.: Drivers and barriers for implementation of environmental strategies in manufacturing companies. CIRP Ann. Manuf. Technol. 62(1), 43–46 (2013) CrossRef Bey, N., Hauschild, M.Z., McAloone, T.C.: Drivers and barriers for implementation of environmental strategies in manufacturing companies. CIRP Ann. Manuf. Technol. 62(1), 43–46 (2013) CrossRef
3.
go back to reference Fijal, T.: An environmental assessment method for cleaner production technologies. J. Clean. Prod. 15(10), 914–919 (2007) CrossRef Fijal, T.: An environmental assessment method for cleaner production technologies. J. Clean. Prod. 15(10), 914–919 (2007) CrossRef
4.
go back to reference May, G., Stahl, B., Taisch, M.: Energy management in manufacturing: toward eco-factories of the future – A focus group study. Appl. Energy 164, 628–638 (2016) CrossRef May, G., Stahl, B., Taisch, M.: Energy management in manufacturing: toward eco-factories of the future – A focus group study. Appl. Energy 164, 628–638 (2016) CrossRef
7.
go back to reference Styles, D., Schoenberger, H., Galvez-Martos, J.L.: Environmental improvement of product supply chains: proposed best practice techniques, quantitative indicators and benchmarks of excellence for retailers. J. Environ. Manag. 110, 135–150 (2012) CrossRef Styles, D., Schoenberger, H., Galvez-Martos, J.L.: Environmental improvement of product supply chains: proposed best practice techniques, quantitative indicators and benchmarks of excellence for retailers. J. Environ. Manag. 110, 135–150 (2012) CrossRef
8.
go back to reference Pusavec, F., Krajnik, P., Kopac, J.: Transitioning to sustainable production – part II: evaluation of sustainable machining technologies. J. Clean. Prod. 18(12), 1211–1221 (2010) CrossRef Pusavec, F., Krajnik, P., Kopac, J.: Transitioning to sustainable production – part II: evaluation of sustainable machining technologies. J. Clean. Prod. 18(12), 1211–1221 (2010) CrossRef
9.
go back to reference Le, V.T., Paris, H., Mandil, G.: Process planning for combined additive and subtractive manufacturing technologies in a remanufacturing context. J. Manuf. Syst. 44, 243–254 (2017) CrossRef Le, V.T., Paris, H., Mandil, G.: Process planning for combined additive and subtractive manufacturing technologies in a remanufacturing context. J. Manuf. Syst. 44, 243–254 (2017) CrossRef
10.
go back to reference Menghi, R., Papetti, A., Germani, M., Marconi, M.: Energy efficiency of manufacturing systems: a review of energy assessment methods and tools. J. Clean Prod. 240, 118276 (2019) CrossRef Menghi, R., Papetti, A., Germani, M., Marconi, M.: Energy efficiency of manufacturing systems: a review of energy assessment methods and tools. J. Clean Prod. 240, 118276 (2019) CrossRef
11.
go back to reference Debnath, K.B., Mourshed, M.: Forecasting methods in energy planning models. Renew. Sustain. Energy Rev. 88, 297–325 (2018) CrossRef Debnath, K.B., Mourshed, M.: Forecasting methods in energy planning models. Renew. Sustain. Energy Rev. 88, 297–325 (2018) CrossRef
12.
go back to reference Boyd, G., Dutrow, E., Tunnessen, W.: The evolution of the ENERGY STAR® energy performance indicator for benchmarking industrial plant manufacturing energy use. J Clean. Prod. 16(6), 709–715 (2008) CrossRef Boyd, G., Dutrow, E., Tunnessen, W.: The evolution of the ENERGY STAR® energy performance indicator for benchmarking industrial plant manufacturing energy use. J Clean. Prod. 16(6), 709–715 (2008) CrossRef
13.
go back to reference May, G., Barletta, I., Stahl, B., Taisch, M.: Energy management in production: a novel method to develop key performance indicators for improving energy efficiency. Appl. Energy 149, 46–61 (2015) CrossRef May, G., Barletta, I., Stahl, B., Taisch, M.: Energy management in production: a novel method to develop key performance indicators for improving energy efficiency. Appl. Energy 149, 46–61 (2015) CrossRef
14.
go back to reference Le, V.T., Paris, H., Mandil, G.: Environmental impact assessment of an innovative strategy based on an additive and subtractive manufacturing combination. J. Clean. Prod. 164, 508–523 (2017) CrossRef Le, V.T., Paris, H., Mandil, G.: Environmental impact assessment of an innovative strategy based on an additive and subtractive manufacturing combination. J. Clean. Prod. 164, 508–523 (2017) CrossRef
15.
go back to reference Papetti, A., Menghi, R., Di Domizio, G., Germani, M., Marconi, M.: Resources value mapping: a method to assess the resource efficiency of manufacturing systems. Appl. Energy 249, 326–342 (2019) CrossRef Papetti, A., Menghi, R., Di Domizio, G., Germani, M., Marconi, M.: Resources value mapping: a method to assess the resource efficiency of manufacturing systems. Appl. Energy 249, 326–342 (2019) CrossRef
16.
go back to reference Gopalakrishnan, B., Ramamoorthy, K., Crowe, E., Chaudhari, S., Latif, H.: A structured approach for facilitating the implementation of ISO 50001 standard in the manufacturing sector. Sustain. Energy Technol. Assess. 7, 154–165 (2014) Gopalakrishnan, B., Ramamoorthy, K., Crowe, E., Chaudhari, S., Latif, H.: A structured approach for facilitating the implementation of ISO 50001 standard in the manufacturing sector. Sustain. Energy Technol. Assess. 7, 154–165 (2014)
17.
go back to reference Zein, A.: Transition towards energy efficient machine tools. Springer, Berlin (2013) Zein, A.: Transition towards energy efficient machine tools. Springer, Berlin (2013)
18.
go back to reference Qureshi, F., Li, W., Kara, S., Herrmann, C.: Unit process energy consumption models for material addition processes: a case of the injection molding process. In: Dornfeld, D., Linke, B. (eds.) Leveraging Technology for a Sustainable World, pp. 269–274. Springer, Berlin, Heidelberg (2012) CrossRef Qureshi, F., Li, W., Kara, S., Herrmann, C.: Unit process energy consumption models for material addition processes: a case of the injection molding process. In: Dornfeld, D., Linke, B. (eds.) Leveraging Technology for a Sustainable World, pp. 269–274. Springer, Berlin, Heidelberg (2012) CrossRef
19.
go back to reference Hopf, H., Müller, E.: Providing energy data and information for sustainable manufacturing systems by energy cards. Robot. Comput.-Integr. Manuf. 36, 76–83 (2015) CrossRef Hopf, H., Müller, E.: Providing energy data and information for sustainable manufacturing systems by energy cards. Robot. Comput.-Integr. Manuf. 36, 76–83 (2015) CrossRef
20.
go back to reference Robinson, D.C., Sanders, D.A., Mazharsolook, E.: Ambient intelligence for optimal manufacturing and energy efficiency. Assem. Autom. 35, 234–248 (2015) CrossRef Robinson, D.C., Sanders, D.A., Mazharsolook, E.: Ambient intelligence for optimal manufacturing and energy efficiency. Assem. Autom. 35, 234–248 (2015) CrossRef
21.
go back to reference Vijayaraghavan, A., Dornfeld, D.: Automated energy monitoring of machine tools. CIRP Ann. Manuf. Technol. 59(1), 21–24 (2010) CrossRef Vijayaraghavan, A., Dornfeld, D.: Automated energy monitoring of machine tools. CIRP Ann. Manuf. Technol. 59(1), 21–24 (2010) CrossRef
22.
go back to reference Vikhorev, K., Greenough, R., Brown, N.: An advanced energy management framework to promote energy awareness. J. Clean. Prod. 43, 103–112 (2013) CrossRef Vikhorev, K., Greenough, R., Brown, N.: An advanced energy management framework to promote energy awareness. J. Clean. Prod. 43, 103–112 (2013) CrossRef
23.
go back to reference Li, Y., Sun, Z., Han, L., Mei, N.: Fuzzy comprehensive evaluation method for energy management systems based on an internet of things. IEEE Access 5, 21312–21322 (2017) CrossRef Li, Y., Sun, Z., Han, L., Mei, N.: Fuzzy comprehensive evaluation method for energy management systems based on an internet of things. IEEE Access 5, 21312–21322 (2017) CrossRef
24.
go back to reference Giacone, E., Mancò, S.: Energy efficiency measurement in industrial processes. Energy 38, 331–345 (2012) CrossRef Giacone, E., Mancò, S.: Energy efficiency measurement in industrial processes. Energy 38, 331–345 (2012) CrossRef
25.
go back to reference Dehning, P., Thiede, S., Mennenga, M., Herrmann, C.: Factors influencing the energy intensity of automotive manufacturing plants. J. Clean. Prod. 142, 2305–2314 (2017) CrossRef Dehning, P., Thiede, S., Mennenga, M., Herrmann, C.: Factors influencing the energy intensity of automotive manufacturing plants. J. Clean. Prod. 142, 2305–2314 (2017) CrossRef
26.
go back to reference Schmidt, M., Raible, C., Keil, R., Graber, M.: Energy and material stream mapping. Institute of Applied Research IAF, Pforzheim University (2007) Schmidt, M., Raible, C., Keil, R., Graber, M.: Energy and material stream mapping. Institute of Applied Research IAF, Pforzheim University (2007)
27.
go back to reference Hamel, M.R. Kaizen event fieldbook: foundation, framework, and standard work for effective events. Society of Manufacturing Engineers (2010) Hamel, M.R. Kaizen event fieldbook: foundation, framework, and standard work for effective events. Society of Manufacturing Engineers (2010)
28.
go back to reference Ohno, T.: Toyota production system: beyond large-scale production. Productivity Press, Newyork (1988) Ohno, T.: Toyota production system: beyond large-scale production. Productivity Press, Newyork (1988)
29.
go back to reference Müller, E., Stock, T., Schillig, R.: A method to generate energy value-streams in production and logistics in respect of time-and energy- consumption. Prod. Eng. 8, 243–251 (2014) CrossRef Müller, E., Stock, T., Schillig, R.: A method to generate energy value-streams in production and logistics in respect of time-and energy- consumption. Prod. Eng. 8, 243–251 (2014) CrossRef
30.
go back to reference Faulkner, W., Badurdeen, F.: Sustainable value stream mapping (Sus-VSM): methodology to visualize and assess manufacturing sustainability performance. J. Clean. Prod. 85, 8–18 (2014) CrossRef Faulkner, W., Badurdeen, F.: Sustainable value stream mapping (Sus-VSM): methodology to visualize and assess manufacturing sustainability performance. J. Clean. Prod. 85, 8–18 (2014) CrossRef
31.
go back to reference Wills, B.: Green intentions: creating a green value stream to compete and win. Productivity Press, New York (2009) Wills, B.: Green intentions: creating a green value stream to compete and win. Productivity Press, New York (2009)
32.
go back to reference Marimin, M.A.D., Machfud, M.P.I.F.P., Bangkit, W.: Value chain analysis for green productivity improvement in the natural rubber supply chain: a case study. J. Clean. Prod. 85, 201–211 (2014) CrossRef Marimin, M.A.D., Machfud, M.P.I.F.P., Bangkit, W.: Value chain analysis for green productivity improvement in the natural rubber supply chain: a case study. J. Clean. Prod. 85, 201–211 (2014) CrossRef
33.
go back to reference Footprint, Carbon.: Country specific electricity grid greenhouse gas emission factors. Carbon Footprint: Hampshire, UK (2019). Footprint, Carbon.: Country specific electricity grid greenhouse gas emission factors. Carbon Footprint: Hampshire, UK (2019).
Metadata
Title
An interactive resource value mapping tool to support the reduction of inefficiencies in smart manufacturing processes
Authors
Marco Marconi
Roberto Menghi
Alessandra Papetti
Giorgia Pietroni
Michele Germani
Publication date
26-07-2021
Publisher
Springer Paris
Published in
International Journal on Interactive Design and Manufacturing (IJIDeM) / Issue 2-3/2021
Print ISSN: 1955-2513
Electronic ISSN: 1955-2505
DOI
https://doi.org/10.1007/s12008-021-00753-5

Other articles of this Issue 2-3/2021

International Journal on Interactive Design and Manufacturing (IJIDeM) 2-3/2021 Go to the issue

Premium Partner