Linking Mass and Energy Flow Analysis with Time Management

Abstract

High cost level of labour and stricter environmental legislation require high material efficiency, but also time efficiency in industrial production. In order to comply with new environmental requirements and to reduce material consumption, product substitutions are necessary, which often affect the current industrial processes. The adaptation of the processes influences mostly also the process duration and consequently the work flow. These changes are being investigated by time and motion studies. This paper proposes the combination of mass and energy flow analysis with results of time and motion studies. The data on time and material consumption can be evaluated simultaneously by using hierarchical IMPROVE®, which has been implemented for vehicle refinishing processes. The model facilitates an integrated process optimisation with regard to environmental and organisational aspects. Moreover, the interaction of changes in time (machine or labour time) and material use caused by product substitution or process changes can be considered. This enhanced approach for mass flow analysis allows for more meaningful environmental performance figures. Additionally, labour costs of process modifications or emission reduction measures can be assessed. Different strategies can be analysed by scenario techniques, supporting decision making and bench marking.