Evaluating the Effects of Energy Productivity Measures on Lean Production Key Performance Indicators

The use of energy in manufacturing processes provides great saving potential. Independent studies estimate possible energy savings up to 30%. In order to benefit from these potentials, manufacturing companies need guidelines, which support them in identifying energy waste. The methodology presented provides a four-step approach to increase energy productivity. After creating transparency with an energy oriented value stream mapping and the identification of possible measures to reduce energy waste, the effects of measures on existing key performance indicators of Lean Production Systems (LPS) are analyzed. For that purpose an impact network was generated, which shows possible effects. Based on that impact network, a generic system dynamics model helps to simulate dynamic effects on important target figures out of the LPS key performance indicators. With that information, manufacturing companies are able to increase energy productivity without having negative effects on existing manufacturing structures.