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The increase of resource (energy and material) efficiency by eliminating unnecessary consumption represents the logical continuation from lean manufacturing to lean and green manufacturing. However, economic efficiency remains the primary decision criterion for the implementation of corresponding strategies. This paper presents a simulation based approach for monetary assessment of lean and green manufacturing systems considering non-monetary green limits. Inclusion of material and energy consumption as well as resulting greenhouse gas emissions enables planners to predict the overall economic performance of a factory. Furthermore, product variant specific footprints of material and energy demands as well as resulting emissions support in-depth analysis of value streams in manufacturing.

This optimisation approach focuses on the shop floor of a manufacturing company. It aims for an integrated lean and green assessment of a manufacturing system and the identification of a cost optimized combination of lean and green strategies with regard to green targets. For green assessment material and energy inputs as well as resulting CO2 emissions are taken into account. Lean assessment focuses on costs and throughput time. Potential lean and green strategies identified during top down analysis are integrated into a discrete event simulation model. This model is connected with optimisation heuristics which improve combined lean and green strategy deployment to the manufacturing system.

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