Abstract Nowadays achieving sustainable development is a global concern. The issue of unsustainability can be related to population growth and excessive consumption of natural resources. To tackle these issues, several management tools and methodologies have been developed in the last years, to assess, analyse and improve the environmental and economic performance of production systems. This work presents an approach based value stream mapping in order to assess and improve energy efficiency, environmental performance and financial performance of a production system. The developed approach can be applied to any industry or production system, where all the unit processes involved are identified and the inputs/outputs of each unit system quantified and easily perceived. Key environmental performance indicators and the corresponding eco efficiency ratios arise as outcomes of this approach, in which a Multi Layer Stream Mapping (MSM) with visual management attributes is created

1. 1PRODU[T]ECH
AUTOMOBILE AND TRANSPORT
AERONAUTICS, SPACE AND DEFENCE
HEALTH
SEA ECONOMY
ENERGY
EQUIPMENT AND DURABLE GOODS
SERVICES
ENVIRONMENT
Multi-Layer Stream Mapping as a Combined
Approach for Industrial Processes
Eco-efficiency Assessment
E.J. Lourenço1, A.J. Baptista1, J.P. Pereira1, and Celia Dias-Ferreira2
1 INEGI - Institute of Mechanical Engineering and Industrial Management,
Campus FEUP, Universidade do Porto, Porto, PORTUGAL
2 CERNAS - Research Center for Natural Resources, Environment and Society,
Campus da Escola Superior Agrária, Coimbra, PORTUGAL
Singapore 17-19 April 2013

2. 2PRODU[T]ECH
Multi-Layer Stream Mapping as a Combined Approach
for Industrial Processes Eco-efficiency Assessment
CIRP – LCE 2013 Singapore, 17-19 April 2013
CONTENTS
1. Introduction
2. Value Stream Mapping: The root for the concept
3. The Multi-layer Stream Mapping Description
4. Strengths of the MSM concept and applicability
5. Application Example
6. Conclusions and Future Work

3. 3PRODU[T]ECH
Multi-Layer Stream Mapping as a Combined Approach
for Industrial Processes Eco-efficiency Assessment
1. Introduction
CIRP – LCE 2013 Singapore, 17-19 April 2013
Eco-efficiency
Last decades economic growth and industrialization lead to major environmental impacts
In the 90’s the World Business Council for Sustainable Development (WBCSD) defined the term
eco-efficiency, which combines ecological and economical efficiency
WBCSD developed a framework to assesses eco-efficiency in order to promote sustainable
development. The main goals are: maximize value creation (more goods/services) and minimize
environmental burdens (less resource consumption and waste creation)
Eco-efficiency measures the relationship between economic growth and environmental
pressure, and is generally expressed by the ratio between economic value and environmental
influence, represented by.
Eco-efficiency
Product or service value
Environmental Influence

4. 4PRODU[T]ECH
Multi-Layer Stream Mapping as a Combined Approach
for Industrial Processes Eco-efficiency Assessment
1. Introduction
CIRP – LCE 2013 Singapore, 17-19 April 2013
Eco-efficiency
Eco-efficiency as a management philosophy towards sustainability can be a very useful tool to
assess environmental and economic performance and enhance the global performance of a
company or even of a production system
The framework developed by WBCSD can be used by any business to assess and measure
progress towards economic and environmental sustainability.
However, this framework lacks a simple and discrete approach in order to analyze and assess
unit processes that are part of a production system

5. 5PRODU[T]ECH
Multi-Layer Stream Mapping as a Combined Approach
for Industrial Processes Eco-efficiency Assessment
1. Introduction
CIRP – LCE 2013 Singapore, 17-19 April 2013
Objectives
Develop a multi-variable combined use of the Value Stream Mapping (VSM) Lean Tool and
demonstrate its suitability to assess environmental and energy performance of unit
processes and production systems in a fast and flexible manner. This by mapping the unit
processes inputs and outputs and assessing their efficiency.
Demonstrate the importance of presenting environmental issues and eco-efficiency
performance in a simple manner through visual management maps and layouts, in order to
simplify top/middle management understanding of the Key Environmental Performance
Indicators (KEPI’s) and their suitability for decision making and overall awareness.
Create an approach that solves the existing eco-efficiency tools and methods that are not
always directly applicable to every product and/or production system, and often addressed
as “isolated stage analysis”.
Create a very easily understandable assessment (for all level collaborators) based in fast
visual management attributes in most methods and tools used for eco-efficiency
assessments.

6. 6PRODU[T]ECH
Multi-Layer Stream Mapping as a Combined Approach
for Industrial Processes Eco-efficiency Assessment
2. Value Stream Mapping: The root for the concept
CIRP – LCE 2013 Singapore, 17-19 April 2013
Value Added vs NON Value Added
A value stream mapping consists basically in the collection of all actions (actions that add
value and actions that do not add value) that are required to bring a product or a group of
products through the main flow, starting with the customer and ending with the raw-
material (upstream).
The primary goal of this tool is to identify all types of waste in the value stream flow and
processes in order to take actions to try and eliminate these, by analyzing the Value Stream
Map.
Example of a common VSM of a Metalworking Industry
Transport
WTS
(input)
Cleaning
WTS
Coating bolt
holes
(manually)
Mixing paint
(pneumatic
mixer)
Applying
primer coat
Drying
primary
coat
Coating
Inspection
2 2 2 2 2 2 2
VA 0,75 h 0,50 h 0,50 h 1,50 h 3,00 h 0,50 h PT 6,75 h
NVA LT 7,89 h
0,38 h 0,03 h 0,20 h 0,15 h 0,15 h 0,06 h WT 1,14 h
86%0,70 h0,53 h1,13 h0,17 h
- 66% 94% 71% 89%
Production
Time (hours)
0,56 h3,15 h1,65 h
0,17 h
91% 95%

7. 7PRODU[T]ECH
Multi-Layer Stream Mapping as a Combined Approach
for Industrial Processes Eco-efficiency Assessment
2. Value Stream Mapping: The root for the concept
CIRP – LCE 2013 Singapore, 17-19 April 2013
The MSM framework combines Value Stream Layers evaluated by the waste elimination /
value creation mindset, identifying the variable part that adds value from the one that does
not add value, with detailed unit process inventory and visual management attributes
The VSM root transforms, in the MSM concept, the understanding of eco-efficiency into
something easily quantifiable, simpler, concise and directly applicable to any production
system, in a process sequence or even in compartmented units
To assess the environmental, financial and global performance of a production system (by the
composition analysis of its subparts), and identifying and quantifying the inefficiencies or
misuses, the MSM concept starts from the classic bathtub curve of Value Stream Mapping
The combined use of Value Stream Layers of a Value Stream Map emerges in order to “see
beyond” the global environmental and financial performance of a production system in a
simpler manner and enable the understanding of the eco-efficiency assessments, and at the
same time simplify the identification and quantification of specific inefficiency situations

8. 8PRODU[T]ECH
Multi-Layer Stream Mapping as a Combined Approach
for Industrial Processes Eco-efficiency Assessment
3. The Multi-layer Stream Mapping Description
CIRP – LCE 2013 Singapore, 17-19 April 2013
The MSM consists in replicating part of the approach used for Value Stream Mapping,
but allowing the addition of multiple layers (stream flows for each process variable) that
embrace environmental and economic aspects, or other variable, to assess eco-efficiency
VSM
MSM
ØTPi
=
PTPi
LTPi
[%]
ØEPi
=
PEPi
TEPi
[%]
ØCPi
=
PCPi
TCPi
[%]
ØXPi
=
PXPi
TXPi
[%]

9. 9PRODU[T]ECH
Multi-Layer Stream Mapping as a Combined Approach
for Industrial Processes Eco-efficiency Assessment
3. The Multi-layer Stream Mapping Description
CIRP – LCE 2013 Singapore, 17-19 April 2013
The values located below of the MSM line are those which do not add value to the product,
i.e. representing the waste/misuses of time, money or resources
The values that are presented above the MSM line (Process Stages) are those that add value
to the product, thus representing the “useful consumption” of stream flow that can be
analyzed in order to assess, evaluate and quantify production efficiency and eco-efficiency
ØTP1
ØTPi
ØTP2
ØEP1
ØEPi
ØEP2
ØCP1
ØCPi
ØCP2
ØXP1
ØXPi
ØXP2

10. 10PRODU[T]ECH
Multi-Layer Stream Mapping as a Combined Approach
for Industrial Processes Eco-efficiency Assessment
3. The Multi-layer Stream Mapping Description
CIRP – LCE 2013 Singapore, 17-19 April 2013
The MSM approach considers dimensionless ratios (actual variable divided by the maximum
of the same variable, on the same process step), so the higher the result for the ratio, the
better the performance of the energy, mass or time flow or other key variable of a
process or system
The process variables, must be assigned consistently to be maximized. The analysis of
variables with the MSM is almost unlimited, for instance, the following environmental aspects
can take place as assessing variables:
Electrical energy
Raw Material
Fuel
CO2 Emissions reduction
Waste elimination
Toxic materials reduction
Beside environmental aspects, other specific cost flows can be added, i.e. cost flow lines to
assess the costs of energy consumption only, or raw material only, thus allowing to assess
specific eco-efficiency indicators (since product value and environmental influence are specific)
For a faster assess of the efficiency quantity, it was added visual management attributes by
relating a very common key of 4 colors (red, orange, yellow, green) in the positive direction of
efficiency, from 0% to 100%

11. 11PRODU[T]ECH
Multi-Layer Stream Mapping as a Combined Approach
for Industrial Processes Eco-efficiency Assessment
3. The Multi-layer Stream Mapping Description
CIRP – LCE 2013 Singapore, 17-19 April 2013
MSM global efficiency dashboard (illustrative data)
Process Stream Analysis
Multi-LayerStreamMapping
Process Efficiency 100 - 90%
Process Efficiency 89 - 70%
Process Efficiency 69 - 40%
Process Efficiency <40%

12. 12PRODU[T]ECH
Multi-Layer Stream Mapping as a Combined Approach
for Industrial Processes Eco-efficiency Assessment
4. Strengths of the MSM concept and applicability
CIRP – LCE 2013 Singapore, 17-19 April 2013
MSM Strengths
The MSM approach can assess, quantify and analyze environmental aspects (energy
consumption, emissions, raw material consumption etc.), economic aspects and productions
aspects one by one for each unit process. On the other hand the global performance can be
assessed and quantified.
One key feature of the MSM approach consists in considering dimensionless ratios, so the
higher the result for the ratio, the better the performance. This feature allows the comparison
of efficiency performance of distinct variables, and combine an integrated quantification of the
overall efficiency, for instance by weighted average or product (by column or row)
The outcome and results are a diagrammatical and intuitive representation of managerial
concepts, and can be very practical and useful for:
Top management decision support
Defining priorities
Identifying inefficiencies in an easy manner
Identifying Key Environmental Performance Indicators (KEPI)
Assessing eco-efficiency performance
Identifying improvement actions needs
Informing all level of collaborators of the efficiency of the production cell or unit

13. 13PRODU[T]ECH
Multi-Layer Stream Mapping as a Combined Approach
for Industrial Processes Eco-efficiency Assessment
4. Strengths of the MSM concept and applicability
CIRP – LCE 2013 Singapore, 17-19 April 2013
MSM Strengths
This approach can also be used for process re-engineering evaluation (multi-scenarios analysis),
since in some cases the unit processes, or even the whole production system of a factory, have
good operational results, but the efficiency is not as high as it could be.
Therefore, using this approach to start point for scrutinize “where”, “how”, and “how much” can
a unit process and/or a production system improve its financial, environmental and performance
aspects, is of great importance for decision-making
It’s simplicity is one great advantage, since it allow a very fast and visual assess of multi-variable
efficiency and its integration (for instance by heighted average), simultaneously for top
management or even workers.

14. 14PRODU[T]ECH
Multi-Layer Stream Mapping as a Combined Approach
for Industrial Processes Eco-efficiency Assessment
4. Strengths of the MSM concept and applicability
CIRP – LCE 2013 Singapore, 17-19 April 2013
(*) If the data inventory exists(*) If the data inventory exists(*) If the data inventory exists(*) If the data inventory exists
… and …… and …… and …… and …
LLLL1111 (line 1) = M(line 1) = M(line 1) = M(line 1) = M11111111 (machine 11) +(machine 11) +(machine 11) +(machine 11) + MMMM1i1i1i1i (machine(machine(machine(machine 1i) +…1i) +…1i) +…1i) +…
LLLL2222 (line(line(line(line 2)2)2)2) ==== MMMM21212121 (machine(machine(machine(machine 21212121) +) +) +) + MMMM2i2i2i2i (machine 2i(machine 2i(machine 2i(machine 2i) +…) +…) +…) +…
MSM drilldown (*)MSM drilldown (*)MSM drilldown (*)MSM drilldown (*)
ProcessesProcessesProcessesProcesses
LinesLinesLinesLines

15. 15PRODU[T]ECH
Multi-Layer Stream Mapping as a Combined Approach
for Industrial Processes Eco-efficiency Assessment
4. Strengths of the MSM concept and applicability
CIRP – LCE 2013 Singapore, 17-19 April 2013
Combine MSM analysis with mapping of layoutsCombine MSM analysis with mapping of layoutsCombine MSM analysis with mapping of layoutsCombine MSM analysis with mapping of layouts
P3
60%
L1
61%
L2
62%
L3
57%

16. 16PRODU[T]ECH
Multi-Layer Stream Mapping as a Combined Approach
for Industrial Processes Eco-efficiency Assessment
4. Strengths of the MSM concept and applicability
CIRP – LCE 2013 Singapore, 17-19 April 2013
Integrate MSM results and layoutsIntegrate MSM results and layoutsIntegrate MSM results and layoutsIntegrate MSM results and layouts
P3
60%
L1 L2
L3
61% 62%
57%
P2
60%
P1
90%
P4
75%
Company
71%
Lines
Plant

17. 17PRODU[T]ECH
Multi-Layer Stream Mapping as a Combined Approach
for Industrial Processes Eco-efficiency Assessment
4. Strengths of the MSM concept and applicability
CIRP – LCE 2013 Singapore, 17-19 April 2013
Other MSM applicationsOther MSM applicationsOther MSM applicationsOther MSM applications Wine Vineyard FarmWine Vineyard FarmWine Vineyard FarmWine Vineyard Farm
Other examples:Other examples:Other examples:Other examples:
HospitalsHospitalsHospitalsHospitals
BuildingsBuildingsBuildingsBuildings
Office units (Services or Engineering)Office units (Services or Engineering)Office units (Services or Engineering)Office units (Services or Engineering)
Transport companiesTransport companiesTransport companiesTransport companies
etc…etc…etc…etc…
BedBedBedBed 2222
BedBedBedBed 3333
BedBedBedBed 1111

18. 18PRODU[T]ECH
Multi-Layer Stream Mapping as a Combined Approach
for Industrial Processes Eco-efficiency Assessment
4. Strengths of the MSM concept and applicability
CIRP – LCE 2013 Singapore, 17-19 April 2013
MSM comparison regarding other performance indicatorsMSM comparison regarding other performance indicatorsMSM comparison regarding other performance indicatorsMSM comparison regarding other performance indicators
The visual management attributes integration and its mathematical simplicity, based on the
well-known VSM lean tool, the MSM can be viewed as a promoter for the importance of
assessing, evaluating and quantifying environmental aspects of an industrial process or plant,
in order to improve global industrial performance

19. 19PRODU[T]ECH
Multi-Layer Stream Mapping as a Combined Approach
for Industrial Processes Eco-efficiency Assessment
5. Application Example
CIRP – LCE 2013 Singapore, 17-19 April 2013
MSM simplified diagramMSM simplified diagramMSM simplified diagramMSM simplified diagram

20. 20PRODU[T]ECH
Multi-Layer Stream Mapping as a Combined Approach
for Industrial Processes Eco-efficiency Assessment
6. Conclusions and Future Work
CIRP – LCE 2013 Singapore, 17-19 April 2013
Develop a mathematical approach for optimization system purposes
Study the application of the results for Life Cycle Engineering decision support, assessing
process/resource usage efficiency vs. process/resource usage eco-efficiency
Study its application in multi-product analysis
Develop data base with environmental impact (single score contribution – Pt) for major/most
common materials and energy types/flows
ConclusionsConclusionsConclusionsConclusions
Future WorkFuture WorkFuture WorkFuture Work
MSM concept, based on the lean tool VSM, brings new perspective on how eco-efficiency
assessments results can be quantified by a discreet method for a process sequence or a individual
system
It integrates strong visual management attributes and is mathematically simple (very easy to use
for all kind of stakeholders)
Very versatile and wide range concept that can be applied for multi-variable and multiple
economic activities (project management, logistics, economics, services, health care, etc.)

21. 21PRODU[T]ECH
Thank You
Multi-Layer Stream Mapping as a Combined Approach for
Industrial Processes Eco-efficiency Assessment
E.J. Lourenço, A.J. Baptista, J.P. Pereira, and Celia Dias-Ferreira
Corresponding author: abaptista@inegi.up.pt
INEGI - Institute of Mechanical Engineering and Industrial Management,
Campus FEUP, Universidade do Porto, Porto, PORTUGAL