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How to increase energy efficiency?
Basic methodology of management
Achieving energy management
  • To reduce Amount of energy consumption and Energy cost,
  • It should be managed,
    by Factory total (whole factory) ---
    by Process Line ---
    by Facility (machine) ---
  • Management in small unit (facilities) is more suitable for improvement of energy intensity than in large unit (factory total).
  • Shown in Energy intensity.
    because, it is easier to evaluate the result of operational/technical improvement comparing with before-improvement.
    We can utilize “the 7 tools” for management and improvement.
Energy intensity (or energy unit consumption)

As the management of energy, “energy intensity” is widely accepted. The definition is:“
Energy intensity” can be applied for “whole factory”, “individual process line”, “each machines”.

“Energy consumption amount”
--- heat (J) and/or electric power (Kwh) (→ combined in crude oil equivalent)
--- can be represented by individual particular unit --- steam: ton, water: m3, fuel: Kl etc.

“Production amount”
--- unit: weight (tonnage), number of products, treated area(m2), working time (h), etc

Example: energy intensity of boiler
  1. The condition of boiler operation
    a. steam production rate (without electric generation) 4,090 ton per month
    b. fuel consumption rate (LHV=41.7 GJ/k-litter) 300 kl per month (bunker-C)
  2. Calculation
    energy intensity of boiler = fuel consumption / steam production = 300,000 l / 4,090 ton
    = 73.3 l-Bunker-C / t-Steam = 3.06 GJ / t-Steam
    the price of Bunker-C is 34,000 Yen / kl, shown by energy cost : 2,492 Yen / t-Steam.
<Japanese way>
TQM and Sho-shudan activity
Key persons: Top management,
Energy manager, Sho-shudan leader

Energy is used everywhere. Energy is used by everybody. → suitable for TQM
Utilization of workers’ ability (incentives for workers and top-management) → Sho-shudan
*TQM and Kaizen by Sho-shudan activity are very popular in Japanese enterprises/factories.
(Sho-shudan activity is generally included in TQM.)

In many cases energy managers play the role of secretaries, advisers, instructors.
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