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Value-Stream Mapping as a Tool to Improve Production and Energy Consumption: A Case Study of a Manufacturer of Industrial Hand Tools

Author

Listed:
  • Mariusz Salwin

    (Institute of Organization of Production Systems, Faculty of Mechanical and Industrial Engineering, Warsaw University of Technology, 85 Narbutta Street, 02-524 Warsaw, Poland)

  • Karolina Pszczółkowska

    (Building Tools Manufacturing Plant, 34 Graniczna Street, 05-094 Janki, Poland)

  • Michał Pałęga

    (Department of Production Management, Faculty of Production Engineering and Materials Technology, Częstochowa University of Technology, 19 Aleja Armii Krajowej, 42-201 Częstochowa, Poland)

  • Andrzej Kraslawski

    (Industrial Engineering and Management, School of Engineering Science, Lappeenranta University of Technology, P.O. Box 20, FI-53581 Lappeenranta, Finland)

Abstract

Manufacturing companies strive to minimize costs, maximize efficiency and improve production quality, which is crucial for market competitiveness. As companies grow and technologies evolve, increasingly complex challenges arise in effectively managing and improving production processes. One of the tools that helps companies improve their processes is value-stream mapping (VSM). The article focuses on the use of VSM in the production process of hand tools used in the construction industry. The paper presents selected aspects of the optimization of the production process using the mapping concept. The research identified and characterized the most important processes occurring in the production of hand tools used in construction. Then, basic data on the value stream was collected and the need for improvements and actions aimed at optimizing the value stream was indicated. Financial results, key performance indicators (KPIs), machine operation and reliability, energy consumption in the production process and overall equipment effectiveness (OEE) before and after improvements were calculated. The analysis carried out allowed for the optimization of the production process in terms of economy and energy consumption. As a result of the improvements, the productivity of injection-molding workers increased by 9.4% and the overall equipment efficiency by 18%. The machine availability rate increased from 70.3% to 85.2%. After implementing the improvements, the company is able to save approximately 295,488 kWh annually, i.e., approximately EUR 53,253, while 1 kWh currently costs producers in Poland EUR 0.18. The conclusions and results described in the paper constitute a solid basis for further development of an improvement project for the selected company.

Suggested Citation

  • Mariusz Salwin & Karolina Pszczółkowska & Michał Pałęga & Andrzej Kraslawski, 2023. "Value-Stream Mapping as a Tool to Improve Production and Energy Consumption: A Case Study of a Manufacturer of Industrial Hand Tools," Energies, MDPI, vol. 16(21), pages 1-25, October.
    • Handle: RePEc:gam:jeners:v:16:y:2023:i:21:p:7292-:d:1268813
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    References listed on IDEAS

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    1. Chandandeep Grewal, 2008. "An initiative to implement lean manufacturing using value stream mapping in a small company," International Journal of Manufacturing Technology and Management, Inderscience Enterprises Ltd, vol. 15(3/4), pages 404-417.
    2. Stadnicka, Dorota & Litwin, Paweł, 2019. "Value stream mapping and system dynamics integration for manufacturing line modelling and analysis," International Journal of Production Economics, Elsevier, vol. 208(C), pages 400-411.
    3. Mariusz Salwin & Ilona Jacyna-Gołda & Michał Bańka & Dari Varanchuk & Anna Gavina, 2021. "Using Value Stream Mapping to Eliminate Waste: A Case Study of a Steel Pipe Manufacturer," Energies, MDPI, vol. 14(12), pages 1-19, June.
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