# Sustainable Transformation: A Case Study of an Engineering-to-Order Additive Manufacturing Firm
## 5 Case Study Company
### Process Analysis through Sus-VSM
#### 5.1.1 Sus-VSM
* Economic evaluation
* The company operates as a local manufacturer situated in close proximity to its customers, minimising supply chain challenges and transportation expenses. * The minimum production timeframe for the assumed theoretical part is 4 days (the lead time would remain consistent for the small batch of parts that can fit into the printer's build volume at once. ); nonetheless, due to potential delays, production duration can extend to several weeks. Several factors impact the production timeline, including the necessity for servicing, machine malfunctions, order complexity, and project completion requirements. Regular machine servicing and cleaning contribute to time delays; for instance, frequent usage of a build unit necessitates recurrent cleaning and repairs. Overtime incurred during waiting periods for service providers to rectify machine issues can also extend production time, with service-related waiting times estimated to range from 2 days to 6 weeks. * The waiting time due to cooling is minimised through the utilisation of multiple natural cooling units within the company's facility. Cooling processes are executed in two distinct methods: natural cooling and rapid cooling. Rapid cooling is achieved through forced ventilation directly within the build unit, significantly reducing the cooling period to 4-6 h. This expedited cooling approach aids in shortening production durations, facilitating swift deliveries to customers. However, it is important to note that rapid cooling can potentially result in partial deformations due to uneven air distribution; also, it can affect the environment as the forced ventilation requires electricity. On the other hand, natural cooling, a slower process, necessitates a minimum of 24 h and occurs within designated natural cooling units. The elimination of natural cooling time is not feasible. To enhance efficiency, especially for substantial orders, the company strategically invested in supplementary natural cooling units. This optimisation effort contributes to the overall streamlining of the production process for large-scale orders. * Defects in parts may necessitate the printing of spare components, resulting in what is recognised as over-processing. This form of waste occurs due to the production of supplementary parts, often unnecessarily, to compensate for potential defects. Figure 3: Sus-VSM for production process with multi-jet fusion (MJF)—current state (The chart was created for the production of a specific component with a volume of 30 cm\({}^{3}\)). Societal evaluation
* The injury rate during the production process is exceptionally low, warranting the characterisation of the process as inherently safe. * The handling of powders poses potential health hazards; hence, environmental risks related to powder handling are effectively mitigated through the utilisation of personal protective equipment (PPE) including safety glasses, gloves, and dust masks. These precautions are particularly observed during activities such as vacuuming unused powder from the processing station. Additionally, heat-resistant gloves are employed for unpacking parts from a build unit in urgent situations where parts are needed and the build unit has not sufficiently cooled down. * If not properly secured, post-processing procedures can pose health risks. To address these concerns, environmental risks associated with post-processing were effectively mitigated through the adoption of a post-processing machine adhering to high safety standards. The case study company utilises the AM solution S1 machine (depicted in Figure 4), designed to prevent operator exposure to moving parts; therefore, additional safety features are deemed unnecessary. This machine also ensures relatively low noise emissions and features airtight machine doors, allowing operators to work without the need for safety glasses or noise protection. The machine components adhere to ATEX standards, further ensuring safety compliance.