Energy Value Stream Mapping (EVSM) as a Tool for the Analysis and Reduction of Energy Consumption in Manufacturing Processes

The Lean Manufacturing concept is one of the most widely applied approaches to improving production processes, enabling greater efficiency, higher quality, and the reduction of various forms of waste. One of its key tools, Value Stream Mapping (VSM), supports a detailed analysis of material and information flows, helping to identify areas for improvement. In recent years, growing attention has been given to evaluating production processes from the perspective of energy efficiency, which has led to the development of an extended version of this tool—Energy Value Stream Mapping (EVSM). This study presents a practical verification of the applicability of the EVSM method for analyzing a manufacturing process in terms of electricity consumption and establishing its energy balance. Based on computer simulation, alternative future-state scenarios were developed and subsequently evaluated within a simulation environment. As a result, the most effective variant was selected, and its implementation demonstrated that for the same production batch, it is possible to reduce total electricity consumption from 485.13 kWh to 418.53 kWh. At the same time, total production lead time was reduced from 26,880 s to 17,833 s (by approximately 33.7%). Electricity consumption during machine operation decreased slightly from 398.86 kWh to 387.34 kWh, while idle energy consumption was significantly reduced from 86.27 kWh to 31.82 kWh. Additionally, the reorganization of production resources led to a reduction—though not a complete elimination—of existing bottlenecks, while the average work-in-process inventory decreased from 27 to 10 units. The results indicate that integrating EVSM with simulation modeling provides an effective approach to improving both energy efficiency and the operational performance of production systems.