The development of a framework to reduce water and energy consumption through the use of water and energy value stream mapping for the South African manufacturing industry

The Republic of South Africa’s energy economy is under immense pressure and the main energy utility, Eskom, cannot reliably generate sufficient electrical energy to meet its customer demand. Water security in South Africa is also under threat as the country is currently amidst a water crisis. The South African manufacturing industry is the sector consuming the largest portion of the total energy consumption and second largest portion of the total water consumption (excluding urban use) nationally. Water and energy efficiency improvement is becoming imperative for organisational success as well as national economic sustainability. This is due to the significant increase in the cost of both electrical energy and water in recent years, and the drop in the reserve energy margin below the minimum level required for sustainable operation of energy utilities. The research objective therefore was to develop a Lean-based water and energy efficiency improvement framework for the manufacturing industry to encourage and realise a reduced demand for energy and water in it. A literature review was conducted on the water and energy landscape in South Africa, Lean manufacturing principles and their positive natural influence on water and energy efficiency, and the Value Stream Mapping tool. The survey of water and energy wastes in the manufacturing industry yielded the creation of standardised water and energy waste categories for use in conjunction with the conventional Lean wastes, tools and techniques. The literature survey indicated that the implementation of Lean manufacturing techniques naturally leads to the improvement of energy and water intensity. The researcher hypothesised that there is even greater potential for water and energy savings if a Lean-based tool is developed to specifically focus on the improvement of energy and water efficiency. A framework for this tool was developed through the literature survey. The tool is based on the Value Stream Mapping tool. A practical experiment was then conducted to establish the effectiveness of the tool in the South African manufacturing industry. The experiment design included an outline of the forecasting and statistical validation techniques to ensure the integrity of data utilised for approving or disproving the set hypotheses. The results of the practical experiment yielded positive results, confirming the hypothesis that the implementation of the developed framework will lead to improved energy and water efficiency in the manufacturing industry. After an explanation of the experimental results, the study concluded with recommendations and conclusions based on the findings