To assess the contribution of this lean approach, the Overall Equipment Effectiveness, (OEE), and manufacturing costs are taken as performance metrics. Therefore, this study explores how the systematic application of VSM in a flexographic printing process can foster further the process improvement when combined with other lean activities, such as, 5S, single minute exchange of die (SMED), and kaizen etc. To enable sustainable continuous process improvements within the printing process, lean manufacturing methodologies, such as Value Stream Mapping, (VSM), can be a competitive management approach. The issues related to setup downtime, raw material waste, and the quality defects are inevitable in the flexographic printing business. This approach can also add to reducing the carbon footprint of the manufacturing process and help companies meet sustainability goals. The results of the research exhibit that the model was efficient and accurate, leading to a reduction in energy consumption and costs while maintaining or even improving the quality of the printed output. Additionally, a multi-linear regression model was developed using machine learning and a range of input parameters, such as machine speed, production meter, substrate density, machine idle time, machine working time, and total machine run time, to predict energy consumption and optimize job scheduling. By implementing the 5Why root cause analysis and Kaizen, the study found that the idle time was reduced by 30% for the Miraflex machine and the F&K machine, resulting in energy savings of 34.198% and 38.635% per meter, respectively. This research combines lean principles and machine learning to improve energy efficiency in selected flexographic printing machines i.e., Miraflex and F&K. A major challenge in flexographic printing is the need to optimize energy usage, which requires diligent attention to resolve. Flexographic printing is a highly sought-after technique within the realm of packaging and labeling due to its versatility, cost-effectiveness, high speed, high-quality images, and environmentally friendly nature.
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