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LEAN ENERGY EFFICIENCY: SCENARIO ANALYSIS OF A REFRIGERATOR PLANT APPLICATION

Year 2024, Volume: 12 Issue: 1, 53 - 68, 01.03.2024
https://doi.org/10.36306/konjes.1251805

Abstract

Energy concern is increasing in the manufacturing companies implementing the most recent technologies. Energy is a major input for many industries and therefore, within the definition of Industry 4.0 new energy efficiency strategies are defined. Energy flexible processes and waste-to-energy are well-known strategies since they are easily implemented in any manufacturing site. Reduction in energy consumption is also facilitated by the preventive maintenance and renewal of the technologies using energy resources. This study aims to apply a lean production method Value Stream Maps (VSM) on energy consumption levels of the processes to evaluate the decision of technology and/or process change. Processes which use energy excessively when compared with the industry average, will be considered as a bottleneck. Using the value stream maps for energy use is accepted as “Lean Energy Efficiency”. Parameters determined by the preparation of these maps will be enriched by interdependencies determined using the Bayesian Belief Network, which will support finding the priorities among the new efficiency activities. This technique will facilitate the decision of repair or buy through priority scenarios showing the possibility of a decision in each scenario. The combination of the Lean Energy Efficiency Method and the Bayesian Belief Network Method will assist the decision-makers in developing more informed and knowledge-based strategies. The case study is realized in a refrigerator factory handling the energy consumption of different departments. Consequently, these findings could be used as a roadmap for the technology renewal investment decisions made by the firm.

References

  • A. Koç, H. Yağlı, K. Yıldız, and İ. Uğurlu, “Dünyada ve Türkiye’de enerji görünümünün genel değerlendirilmesi,” Mühendis ve Makina, 59(692), pp.86-114, 2018.
  • L. Castellazzi, T. Serrenho, M. Economidou, and P. Zangheri, “Energy Consumption and Energy Efficiency trends in the EU-28. 2000-2018”, 2020.
  • (EPA) Environmental Protection Agency, “Final Effluent Guidelines Program Plan 14 Documents. Final Effluent Guidelines Program Plan 14 – Overview,” Jan. 2021.
  • M.K. Lim, M. Lai, C. Wang, and Y. Lee, “Circular economy to ensure production operational sustainability: A green-lean approach,” Sustainable Production and Consumption, 30, pp.130-144, 2022.
  • Middle Black Sea Development Agency, “Guide to Incentives and Supports Provided in Turkey,” https://www.oka.org.tr/assets/upload/dosyalar/turkiyede-saglanan-tesvik-ve-destekler-25-78.pdf Accessed 28.10.2019
  • O. Türkyılmaz, and C. Özgiresun, “Türkiye Enerji Görünümü 2013,” Türkiye Makine Mühendisleri Odası Birliği, 2013,
  • M. Sciortino, S. Watson, and R. Presnar, “The importance of energy efficiency in lean manufacturing: declaring energy the ninth waste,” Proceedings of the 2009 Summer Study on Energy Efficiency in Industry, 3, pp.113-122.R, 2009.
  • C. Tian, G. Feng, S. Li, and F. Xu, “Scenario analysis on energy consumption and CO2 emissions reduction potential in building heating sector at community level,” Sustainability, 11(19), 5392, 2019.
  • M. Haragovics, and P. Mizsey, “A novel application of exergy analysis: Lean manufacturing tool to improve energy efficiency and flexibility of hydrocarbon processing,” Energy, 77, 382-390, 2014.
  • S. Yang, L. Zhang, N. Xie, Z. Gu, and Z. Liu, Z, “Thermodynamic analysis of a semi-lean solution process for energy saving via rectisol wash technology,” Energy, 226, 120402, 2021.
  • U. Kumar, and R. Shankar, “Application of Value Stream Mapping for Lean Operation: An Indian Case Study of a Dairy Firm,” Global Business Review, 09721509221113002, 2022.
  • A. Trubetskaya, O. McDermott, & S. McGovern, “Implementation of an ISO 50001 energy management system using Lean Six Sigma in an Irish dairy: a case study,” The TQM Journal, 35(9), 1-24 2023.
  • X. Wen, H. Cao, B. Hon, E. Chen, and H. Li, “Energy value mapping: A novel lean method to integrate energy efficiency into production management,” Energy, 217, 119353, 2021.
  • N. Verma, V. Sharma, and M.A. Badar, “Entropy-based lean, energy and six sigma approach to achieve sustainability in manufacturing system” Arabian Journal for Science and Engineering, 46(8), pp.8105-8117, 2021.
  • R. Shah, and P.T. Ward, “Defining and Developing Measures of Lean Production. Journal of Operations Management,” 25(4), 785-805, 2007.
  • P. J. Womack, J. T. Daniel, and D. Ross, “Dünyayı Değiştiren Makine” Çeviri Osman Kabak, İstanbul, Panel Matbaacılık, 1990.
  • E.B. Sarı, “Yalın üretim uygulamaları ve kazanımları” Uluslararası İktisadi ve İdari İncelemeler Dergisi, 17, pp.585-600, 2018.
  • Z. Hao, C. Liu, and M. Goh, “Determining the effects of lean production and servitization of manufacturing on sustainable performance,” Sustainable Production and Consumption, 25, pp.374-389, 2021.
  • A. Kiliç, and B. Ayvaz, “Türkiye otomotiv yan sanayinde yalin üretim uygulamasi/a lean manufacturing application in Turkish automotive industry, “ Istanbul Ticaret Universitesi Fen Bilimleri Dergisi. 15(29), p.29, 2016.
  • J. Bhamu, A. Khandelwal, and K.S. Sangwan, “Lean manufacturing implementation in an automated production line: a case study,” International Journal of Services and Operations Management, 15(4), pp.411-429, 2013.
  • A. Gurumurthy, and R. Kodali, “Design of lean manufacturing systems using value stream mapping with simulation: a case study,” Journal of manufacturing technology management, 22(4), pp. 444-473, 2011.
  • E. Yılmaz, “Siparişe göre üretim yapan sistemlerde yalın üretim uygulamaları” (Doctoral dissertation, Fen Bilimleri Enstitüsü) ,2013.
  • S.M. James‐Moore, and A. Gibbons, “Is lean manufacture universally relevant? An investigative methodology,” International Journal of Operations & Production Management, 17(9), pp.899-911, 1997.
  • J.P. Womack, and D.T. Jones, “Lean thinking—banish waste and create wealth in your corporation,” Journal of the Operational Research Society, 48(11), pp.1148-1148, 1997.
  • R. Balocco, A. Cavallo, A. Ghezzi, and J. Berbegal-Mirabent, “Lean business models change process in digital entrepreneurship,” Business Process Management Journal, 25(7), pp.1520-1542, 2019.
  • C. Keskin, U. Asan, and G. Kayakutlu, “Value stream maps for industrial energy efficiency,” In Assessment and simulation tools for sustainable energy systems, pp. 357-379, Springer, London, 2013.
  • E.A. Abdelaziz, R. Saidur, and S. Mekhilef, “A review on energy saving strategies in industrial sector,” Renewable and sustainable energy reviews, 15(1), pp.150-168, 2011.
  • İ. Kavaz, “Sürdürülebilirlik Politikaları Çerçevesinde Enerji Verimliliği,” SETA Analiz. 287, pp.1-8, 2019.
  • R. Gazete, “Enerji Kaynaklarının ve Enerjinin Kullanımında Verimliliğin Artırılmasına Dair Yönetmelik”, 2011.
  • Productivity Enhancing Projects, “Renewable Energy General Directorate” http://www.yegm.gov.tr/verimlilik/d_VAP.aspx| Accessed 28.10.2019
  • P.J. Martínez-Jurado, and J. Moyano-Fuentes, “Lean management, supply chain management and sustainability: a literature review,” Journal of Cleaner Production. 85, pp.134-150, 2014.
  • D. Kiss, “Using kaizen to reduce energy consumption,”2009.
  • V. Gogula, H.D. Wan, and G. Kuriger, “Impact of lean tools on energy consumption,” Sistemas & Telemática, 9(19), pp.33-53, 2011.
  • M.J. Rivas Duarte, J. Cosgrove, and F. Hardiman, “A Methodology for Process and Energy Mapping In Production Operations,” InImpact: The Journal of Innovation Impact, 8(2), p.412, 2016.
  • E.V. Fraizer, and S. Mitra, “Methodological and interpretive issues in posture-cognition dual-tasking in upright stance,” Gait & posture, 27(2), pp.271-279, 2008.
  • M. Schmidt, C. Raible, R. Keil, and M. Gräber, “Energy and material stream mapping. Recovery of Materials and Energy for Resource Efficiency,” Davos. 7, pp.3-5, 2007.
  • N. Patel, N. Chauhan, and M.P. Trivedi, “Benefits of value stream mapping as a lean tool implementation manufacturing industries: a review,” Int. J. Innov. Res. Sci. Technol., 1(8), pp.53-57, 2015.
  • H. İ., Dağ, and K. A. R. A. Yakup, “Yalın Üretime Geçişte Değer Akişi Analizi Ve Haritalandirma İle İsraf Kaynaklarinin Belirlenmesi: Güneş Enerjisi Kollektörleri Üreten Bir İşletmede Uygulama,” Konya Journal of Engineering Sciences, 8(3), 652-665, 2009.
  • S. Shahid, S. Chacko, and C.M. Shukla, “Energy conservation for a paint company using lean manufacturing technique,” Universal J. Ind. Bus. Manag., 1(3), pp.83-89, 2013.
  • J. Pearl, Probabilistic reasoning in intelligent systems: networks of plausible inference. Morgan kaufmann, 1988.
  • O. Varis, and S. Kuikka, “Learning Bayesian decision analysis by doing: lessons from environmental and natural resources management,” Ecological Modelling, 119(2-3), pp.177-195, 1999.
  • O. Varis, “Bayesian decision analysis for environmental and resource management,” Environmental Modelling & Software,12(2-3), pp.177-185, 1997.
  • M.A. Orzechowski, “Measuring housing preferences using virtual reality and Bayesian belief networks,” 2002.
  • P. Goyal, and U. Chanda, “A Bayesian Network Model on the association between CSR, perceived service quality and customer loyalty in Indian Banking Industry,” Sustainable Production and Consumption, 10, pp.50-65, 2017.
  • E. Alpaydın, “Introduction to Machine Learning”, The MIT Press, Cambridge, London, England, 2004.
  • L. Oteniya, “Bayesian belief networks for dementia diagnosis and other applications: a comparison of hand-crafting and construction using a novel data driven technique”, 2008.
  • M. Neil, P. Krause, and N. Fenton, “Software quality prediction using Bayesian networks,” In Software engineering with computational intelligence, pp. 136-172. Springer, Boston, MA., 2003.
  • E. Aktaş, F. Ülengin, and Ş.Ö. Şahin, “A decision support system to improve the efficiency of resource allocation in healthcare management,” Socio-Economic Planning Sciences, 41(2), pp.130-146, 2007.
  • S. Gupta, and H.W. Kim, “Linking structural equation modeling to Bayesian networks: Decision support for customer retention in virtual communities,” European Journal of Operational Research, 190(3), pp.818-833, 2008.
  • A. Dereli, “Tedarik riskleri altında tedarikçi seçiminin Bayes ağlarıyla modellenmesi” (Doctoral dissertation, Fen Bilimleri Enstitüsü), 2014.
  • D. Cinar, and G. Kayakutlu, “Scenario analysis using Bayesian networks: A case study in energy sector,” Knowledge-Based Systems, 23(3), pp.267-276, 2010.
  • B. Jones, I. Jenkinson, Z. Yang, and J. Wang, “The use of Bayesian network modelling for maintenance planning in a manufacturing industry,” Reliability Engineering & System Safety, 95(3), pp.267-277, 2010.
  • J.G Caballero, “Measuring the effect of organisational factors using Bayesian Networks” (Doctoral dissertation, PhD thesis, Queen Mary University, part of the University of London, 2005. draft) ,2005.
Year 2024, Volume: 12 Issue: 1, 53 - 68, 01.03.2024
https://doi.org/10.36306/konjes.1251805

Abstract

References

  • A. Koç, H. Yağlı, K. Yıldız, and İ. Uğurlu, “Dünyada ve Türkiye’de enerji görünümünün genel değerlendirilmesi,” Mühendis ve Makina, 59(692), pp.86-114, 2018.
  • L. Castellazzi, T. Serrenho, M. Economidou, and P. Zangheri, “Energy Consumption and Energy Efficiency trends in the EU-28. 2000-2018”, 2020.
  • (EPA) Environmental Protection Agency, “Final Effluent Guidelines Program Plan 14 Documents. Final Effluent Guidelines Program Plan 14 – Overview,” Jan. 2021.
  • M.K. Lim, M. Lai, C. Wang, and Y. Lee, “Circular economy to ensure production operational sustainability: A green-lean approach,” Sustainable Production and Consumption, 30, pp.130-144, 2022.
  • Middle Black Sea Development Agency, “Guide to Incentives and Supports Provided in Turkey,” https://www.oka.org.tr/assets/upload/dosyalar/turkiyede-saglanan-tesvik-ve-destekler-25-78.pdf Accessed 28.10.2019
  • O. Türkyılmaz, and C. Özgiresun, “Türkiye Enerji Görünümü 2013,” Türkiye Makine Mühendisleri Odası Birliği, 2013,
  • M. Sciortino, S. Watson, and R. Presnar, “The importance of energy efficiency in lean manufacturing: declaring energy the ninth waste,” Proceedings of the 2009 Summer Study on Energy Efficiency in Industry, 3, pp.113-122.R, 2009.
  • C. Tian, G. Feng, S. Li, and F. Xu, “Scenario analysis on energy consumption and CO2 emissions reduction potential in building heating sector at community level,” Sustainability, 11(19), 5392, 2019.
  • M. Haragovics, and P. Mizsey, “A novel application of exergy analysis: Lean manufacturing tool to improve energy efficiency and flexibility of hydrocarbon processing,” Energy, 77, 382-390, 2014.
  • S. Yang, L. Zhang, N. Xie, Z. Gu, and Z. Liu, Z, “Thermodynamic analysis of a semi-lean solution process for energy saving via rectisol wash technology,” Energy, 226, 120402, 2021.
  • U. Kumar, and R. Shankar, “Application of Value Stream Mapping for Lean Operation: An Indian Case Study of a Dairy Firm,” Global Business Review, 09721509221113002, 2022.
  • A. Trubetskaya, O. McDermott, & S. McGovern, “Implementation of an ISO 50001 energy management system using Lean Six Sigma in an Irish dairy: a case study,” The TQM Journal, 35(9), 1-24 2023.
  • X. Wen, H. Cao, B. Hon, E. Chen, and H. Li, “Energy value mapping: A novel lean method to integrate energy efficiency into production management,” Energy, 217, 119353, 2021.
  • N. Verma, V. Sharma, and M.A. Badar, “Entropy-based lean, energy and six sigma approach to achieve sustainability in manufacturing system” Arabian Journal for Science and Engineering, 46(8), pp.8105-8117, 2021.
  • R. Shah, and P.T. Ward, “Defining and Developing Measures of Lean Production. Journal of Operations Management,” 25(4), 785-805, 2007.
  • P. J. Womack, J. T. Daniel, and D. Ross, “Dünyayı Değiştiren Makine” Çeviri Osman Kabak, İstanbul, Panel Matbaacılık, 1990.
  • E.B. Sarı, “Yalın üretim uygulamaları ve kazanımları” Uluslararası İktisadi ve İdari İncelemeler Dergisi, 17, pp.585-600, 2018.
  • Z. Hao, C. Liu, and M. Goh, “Determining the effects of lean production and servitization of manufacturing on sustainable performance,” Sustainable Production and Consumption, 25, pp.374-389, 2021.
  • A. Kiliç, and B. Ayvaz, “Türkiye otomotiv yan sanayinde yalin üretim uygulamasi/a lean manufacturing application in Turkish automotive industry, “ Istanbul Ticaret Universitesi Fen Bilimleri Dergisi. 15(29), p.29, 2016.
  • J. Bhamu, A. Khandelwal, and K.S. Sangwan, “Lean manufacturing implementation in an automated production line: a case study,” International Journal of Services and Operations Management, 15(4), pp.411-429, 2013.
  • A. Gurumurthy, and R. Kodali, “Design of lean manufacturing systems using value stream mapping with simulation: a case study,” Journal of manufacturing technology management, 22(4), pp. 444-473, 2011.
  • E. Yılmaz, “Siparişe göre üretim yapan sistemlerde yalın üretim uygulamaları” (Doctoral dissertation, Fen Bilimleri Enstitüsü) ,2013.
  • S.M. James‐Moore, and A. Gibbons, “Is lean manufacture universally relevant? An investigative methodology,” International Journal of Operations & Production Management, 17(9), pp.899-911, 1997.
  • J.P. Womack, and D.T. Jones, “Lean thinking—banish waste and create wealth in your corporation,” Journal of the Operational Research Society, 48(11), pp.1148-1148, 1997.
  • R. Balocco, A. Cavallo, A. Ghezzi, and J. Berbegal-Mirabent, “Lean business models change process in digital entrepreneurship,” Business Process Management Journal, 25(7), pp.1520-1542, 2019.
  • C. Keskin, U. Asan, and G. Kayakutlu, “Value stream maps for industrial energy efficiency,” In Assessment and simulation tools for sustainable energy systems, pp. 357-379, Springer, London, 2013.
  • E.A. Abdelaziz, R. Saidur, and S. Mekhilef, “A review on energy saving strategies in industrial sector,” Renewable and sustainable energy reviews, 15(1), pp.150-168, 2011.
  • İ. Kavaz, “Sürdürülebilirlik Politikaları Çerçevesinde Enerji Verimliliği,” SETA Analiz. 287, pp.1-8, 2019.
  • R. Gazete, “Enerji Kaynaklarının ve Enerjinin Kullanımında Verimliliğin Artırılmasına Dair Yönetmelik”, 2011.
  • Productivity Enhancing Projects, “Renewable Energy General Directorate” http://www.yegm.gov.tr/verimlilik/d_VAP.aspx| Accessed 28.10.2019
  • P.J. Martínez-Jurado, and J. Moyano-Fuentes, “Lean management, supply chain management and sustainability: a literature review,” Journal of Cleaner Production. 85, pp.134-150, 2014.
  • D. Kiss, “Using kaizen to reduce energy consumption,”2009.
  • V. Gogula, H.D. Wan, and G. Kuriger, “Impact of lean tools on energy consumption,” Sistemas & Telemática, 9(19), pp.33-53, 2011.
  • M.J. Rivas Duarte, J. Cosgrove, and F. Hardiman, “A Methodology for Process and Energy Mapping In Production Operations,” InImpact: The Journal of Innovation Impact, 8(2), p.412, 2016.
  • E.V. Fraizer, and S. Mitra, “Methodological and interpretive issues in posture-cognition dual-tasking in upright stance,” Gait & posture, 27(2), pp.271-279, 2008.
  • M. Schmidt, C. Raible, R. Keil, and M. Gräber, “Energy and material stream mapping. Recovery of Materials and Energy for Resource Efficiency,” Davos. 7, pp.3-5, 2007.
  • N. Patel, N. Chauhan, and M.P. Trivedi, “Benefits of value stream mapping as a lean tool implementation manufacturing industries: a review,” Int. J. Innov. Res. Sci. Technol., 1(8), pp.53-57, 2015.
  • H. İ., Dağ, and K. A. R. A. Yakup, “Yalın Üretime Geçişte Değer Akişi Analizi Ve Haritalandirma İle İsraf Kaynaklarinin Belirlenmesi: Güneş Enerjisi Kollektörleri Üreten Bir İşletmede Uygulama,” Konya Journal of Engineering Sciences, 8(3), 652-665, 2009.
  • S. Shahid, S. Chacko, and C.M. Shukla, “Energy conservation for a paint company using lean manufacturing technique,” Universal J. Ind. Bus. Manag., 1(3), pp.83-89, 2013.
  • J. Pearl, Probabilistic reasoning in intelligent systems: networks of plausible inference. Morgan kaufmann, 1988.
  • O. Varis, and S. Kuikka, “Learning Bayesian decision analysis by doing: lessons from environmental and natural resources management,” Ecological Modelling, 119(2-3), pp.177-195, 1999.
  • O. Varis, “Bayesian decision analysis for environmental and resource management,” Environmental Modelling & Software,12(2-3), pp.177-185, 1997.
  • M.A. Orzechowski, “Measuring housing preferences using virtual reality and Bayesian belief networks,” 2002.
  • P. Goyal, and U. Chanda, “A Bayesian Network Model on the association between CSR, perceived service quality and customer loyalty in Indian Banking Industry,” Sustainable Production and Consumption, 10, pp.50-65, 2017.
  • E. Alpaydın, “Introduction to Machine Learning”, The MIT Press, Cambridge, London, England, 2004.
  • L. Oteniya, “Bayesian belief networks for dementia diagnosis and other applications: a comparison of hand-crafting and construction using a novel data driven technique”, 2008.
  • M. Neil, P. Krause, and N. Fenton, “Software quality prediction using Bayesian networks,” In Software engineering with computational intelligence, pp. 136-172. Springer, Boston, MA., 2003.
  • E. Aktaş, F. Ülengin, and Ş.Ö. Şahin, “A decision support system to improve the efficiency of resource allocation in healthcare management,” Socio-Economic Planning Sciences, 41(2), pp.130-146, 2007.
  • S. Gupta, and H.W. Kim, “Linking structural equation modeling to Bayesian networks: Decision support for customer retention in virtual communities,” European Journal of Operational Research, 190(3), pp.818-833, 2008.
  • A. Dereli, “Tedarik riskleri altında tedarikçi seçiminin Bayes ağlarıyla modellenmesi” (Doctoral dissertation, Fen Bilimleri Enstitüsü), 2014.
  • D. Cinar, and G. Kayakutlu, “Scenario analysis using Bayesian networks: A case study in energy sector,” Knowledge-Based Systems, 23(3), pp.267-276, 2010.
  • B. Jones, I. Jenkinson, Z. Yang, and J. Wang, “The use of Bayesian network modelling for maintenance planning in a manufacturing industry,” Reliability Engineering & System Safety, 95(3), pp.267-277, 2010.
  • J.G Caballero, “Measuring the effect of organisational factors using Bayesian Networks” (Doctoral dissertation, PhD thesis, Queen Mary University, part of the University of London, 2005. draft) ,2005.
There are 53 citations in total.

Details

Primary Language English
Subjects Engineering
Journal Section Research Article
Authors

Kazım Albayrak 0000-0002-3890-1985

İrem Duzdar Argun 0000-0002-7642-8121

Gülgün Kayakutlu 0000-0001-8548-6377

Özgür Kayalıca 0000-0001-9828-7385

Publication Date March 1, 2024
Submission Date March 3, 2023
Acceptance Date December 19, 2023
Published in Issue Year 2024 Volume: 12 Issue: 1

Cite

IEEE K. Albayrak, İ. Duzdar Argun, G. Kayakutlu, and Ö. Kayalıca, “LEAN ENERGY EFFICIENCY: SCENARIO ANALYSIS OF A REFRIGERATOR PLANT APPLICATION”, KONJES, vol. 12, no. 1, pp. 53–68, 2024, doi: 10.36306/konjes.1251805.