Lean and Green Manufacturing Operationalization Through Multi-Layer Stream Mapping – Lean&Green 4.0

Lean and green (L&G) manufacturing in Industry 4.0 (I4.0) has brought many advantages in manufacturing industries by minimizing waste and maximizing efficiency with integration of renewable energy sources and sustainable materials. Multi-layer Stream Mapping (MSM) is a new framework for the performance assessment of complex manufacturing processes. MSM is used for multi-domain analysis of manufacturing processes to assess resources, and processes, that are used to identify Non-Value Added (NVA) procedures or steps that consume unnecessary time and resources, and/or release emissions and waste that can no longer be reused or recycled to be eliminated or replaced to create a Value Added (VA) process flow that avoids waste in a clean, green and environmental friendly manner. This paper presents the implementation of the L&G strategy through MSM in metalworking production systems. In metalworking production systems, the variables of operational performance and resources consumption considered are process time, number of operators, consumables, raw material, and energy. These can be suitably used for reduction in water emissions, gas emissions, solid waste and scrap generated in metalworking production systems.