Providing a Green Value Stream Map to Improve Production Performance

Abstract

Today, the cement industry has gone through a growing trend. Achieving the country’s economic development, social development, and cultural development goals is essential. However, in line with these benefits, the environmental damage caused by cement factories is inevitable. In the present research, which was carried out to reduce environmental losses, value flow mapping and simulation by Arena software were used in two stages. It was determined in the first stage using the current simulated situation and the waste and environmental pollution created. Then by redrawing the future value flow map and using experts’ opinions, the amount of reduced pollution caused by some measures was estimated. Then, in the second stage a new simulation was done to evaluate the reduced environmental pollution. The results of this research showed that by using the methods mentioned above in the primary production line process of the cement company, about 30% of waste and pollutions were reduced.

Keywords

value stream mapping / simulation / lean production / waste / cement industry / green approach

References

[1] Singh, A., Philip, D., Ramkumar, J., & Das, M. (2018). A simulation based approach to realize green factory from unit green manufacturing processes. Journal of Cleaner Production, 182, 67-81. https://doi.org/10.1016/j.jclepro.2018.02.025

[2] Balkhi, B., Alshahrani, A., & Khan, A. (2022). Just-in-time approach in healthcare inventory management: Does it really work? Saudi Pharmaceutical Journal, 30(12), 1830-1835. https://doi.org/10.1016/j.jsps.2022.10.013

[3] Mohan, J., Rathi, R., Kaswan, M. S., & Nain, S. S. (2022). Green lean six sigma journey: Conceptualization and realization. Materials Today: Proceedings, 50, 1991-1998. https://doi.org/10.1016/j.matpr.2021.09.338

[4] Jum’a, L., Zimon, D., Ikram, M., & Madzík, P. (2022). Towards a sustainability paradigm; the nexus between lean green practices, sustainability-oriented innovation and Triple Bottom Line. International Journal of Production Economics, 245, 108393. https://doi.org/10.1016/j.ijpe.2021.108393

[5] Aalavi, S., & Janatyan, N. (2021). Identifying and prioritizing activities of green project management based on lean-sustainable principles in Isfahan Parks and Green Space Organization. Research in Production and Operations Management, 11(4), 1-25. http://doi.org/10.22108/JPOM.2021.126382.1316

[6] Huang, Z., Kim, J., Sadri, A., Dowey, S., & Dargusch, M. S. (2019). Industry 4.0: Development of a multi-agent system for dynamic value stream mapping in SMEs. Journal of Manufacturing Systems, 52, 1-12. https://doi.org/10.1016/j.jmsy.2019.05.001

[7] Silvestri, L., Gallo, T., & Silvestri, C. (2022). Which tools are needed to implement Lean Production in an Industry 4.0 environment? A literature review. Procedia Computer Science, 200, 1766-1777. https://doi.org/10.1016/j.procs.2022.01.377

[8] Galvão, G. D. A., Homrich, A. S., Geissdoerfer, M., Evans, S., Ferrer, P. S. S., & Carvalho, M. M. (2020). Towards a value stream perspective of circular business models. Resources, Conservation and Recycling, 162, 105060. https://doi.org/10.1016/j.resconrec.2020.105060

[9] de Oliveira, J. A., Devos Ganga, G. M., Godinho Filho, M., Silva, D. A. L., dos Santos, M. P., Aldaya Garde, I. A., ..., & Ometto, A. R. (2022). Environmental and operational performance is not always achieved when combined with cleaner production and lean production: An overview for emerging economies. Journal of Environmental Planning and Management, 65(8), 1530-1559. https://doi.org/10.1080/09640568.2021.1940888

[10] Orisaremi, K. K., Chan, F. T., Chung, S. H., & Fu, X. (2022). A sustainable lean production framework based on inverse DEA for mitigating gas flaring. Expert Systems with Applications, 206, 117856. https://doi.org/10.1016/j.eswa.2022.117856

[11] Mofolasayo, A., Young, S., Martinez, P., & Ahmad, R. (2022). How to adapt lean practices in SMEs to support Industry 4.0 in manufacturing. Procedia Computer Science, 200, 934-943. https://doi.org/10.1016/j.procs.2022.01.291

[12] Kong, L., Wang, L., Li, F., & Guo, J. (2022). Toward product green design of modeling, assessment, optimization, and tools: A comprehensive review. The International Journal of Advanced Manufacturing Technology, 122(5), 2217-2234. https://doi.org/10.1007/s00170-022-10021-9

[13] Agyabeng-Mensah, Y., Tang, L., Afum, E., Baah, C., & Dacosta, E. (2021). Organisational identity and circular economy: Are inter and intra organisational learning, lean management and zero waste practices worth pursuing? Sustainable Production and Consumption, 28, 648-662. https://doi.org/10.1016/j.spc.2021.06.018

[14] Benhelal, E., Shamsaei, E., & Rashid, M. I. (2021). Challenges against CO₂ abatement strategies in cement industry: A review. Journal of Environmental Sciences, 104, 84-101. https://doi.org/10.1016/j.jes.2020.11.020

[15] Alavi, S., Peivandzani, S., & Mirmohammadsadeghi, S. (2021). Risk assessment and prioritization of ERP implementation based on BSC. Journal of Human, Earth, and Future, 2(1), 16-23. https://doi.org/10.28991/HEF-2021-02-01-02

[16] Mishra, U. C., Sarsaiya, S., & Gupta, A. (2022). A systematic review on the impact of cement industries on the natural environment. Environmental Science and Pollution Research, 29(13), 18440-18451. https://doi.org/10.1007/s11356-022-18672-7

[17] Ighalo, J. O., & Adeniyi, A. G. (2020). A perspective on environmental sustainability in the cement industry. Waste Disposal & Sustainable Energy, 2(3), 161-164. https://doi.org/10.1007/s42768-020-00043-y

[18] Alavi, S., Arbab Shirani, B., & Esfandiari, E. (2014). Investigation about the relationship between organizational learning and innovation from system dynamic view in Isfahan engineering research center. Research in Production and Operations Management, 5(1), 71-92. https://jpom.ui.ac.ir/article_19807_en.html

[19] Kumar, N., Hasan, S. S., Srivastava, K., Akhtar, R., Yadav, R. K., & Choubey, V. K. (2022). Lean manufacturing techniques and its implementation: A review. Materials Today: Proceedings, 64, 1188-1192. https://doi.org/10.1016/j.matpr.2022.03.481

[20] Mirmohammadsadeghi, S., Ahmed, S., & Nadirah, E. (2014). Application of memetic algorithm to solve truck and trailer routing problems. In Proceedings of the 2014 International Conference on Industrial Engineering and Operations Management, 747-755.

[21] Poudyal, L., & Adhikari, K. (2021). Environmental sustainability in cement industry: An integrated approach for green and economical cement production. Resources, Environment and Sustainability, 4, 100024. https://doi.org/10.1016/j.resenv.2021.100024

[22] Dinga, C. D., & Wen, Z. (2022). China’s green deal: Can China’s cement industry achieve carbon neutral emissions by 2060? Renewable and Sustainable Energy Reviews, 155, 111931. https://doi.org/10.1016/j.rser.2021.111931

[23] Schneider, M. (2019). The cement industry on the way to a low-carbon future. Cement and Concrete Research, 124, 105792. https://doi.org/10.1016/j.cemconres.2019.105792