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METI/ECCJ/AOTS Training Program Indonesia

Example 2: Dust Removal System in Foundry
Power cost reduced with small amount of suction air.
Example 3: Manufacturing process improvement --- Eliminating heating process
Factory: Car parts --- alternator stator manufacturing process
Before improvement Diode is soldered to the fin, therefore solder heating furnace is necessary.
After improvement Diode is attached by press-in process to the fin, and heating/cooling process is eliminated.

Required technical development: To avoid the strain in diode.
To secure the adhere to the fin.

Small Group Improvement Approaches
  • Identifying and analyzing the current situation
    • The same operators form a group.
    • Identify the actual energy consumption by group operations.
    • Perform measurement by operation condition and draw a graph of the tendency.
    • Operation conditions: Products, processes, etc.
    • Fuel, electric power, steam, compressed air, water, nitrogen
  • Detecting problems and reviewing improvements
    • Discussion by group members
    • Improvement planning: Using engineering staff and external information (from manufacturers, etc.)
    • Evaluating improvement proposals: Reliability and operation- and quality-related performance of technology, cost, and effects
  • Implementing improvements
    • The internal energy committee adopts and implements (carries out) improvements.
  • Confirming effects, standardizing operations, development of improvements to other departments
Case Presentation Meetings
  • Branch presentation meeting
    • A branch presentation meeting is held at eight branches of the Energy Conservation Center in Japan.
    • All entrant groups present their activities, and judges and public audiences sit in on here meetings.
  • Central presentation meeting
    • The central presentation meeting is held in each February, the energy conservation month.
    • Each presentation meeting is held for two days at the same location as ENEX (an exhibition) in Tokyo and Osaka.
    • Prize-winning cases (57 cases in 2003F.Y.) were presented (the Minister of Economy, Trade and Industry Prize and the Chief of the Agency of Natural Resources and Energy Prize are given in both locations, and others are given in only one location).
    • The total number of audience was 1,830 (1,030 in Tokyo, 800 in Osaka).
    • Attendance at the meeting and a question-and-answer session is free of charge.
    • Besides details of technology, approaches to and ideas for how to push forward with improvements can be obtained.
    • All cases can be seen on ECC's net-site (eccj.or.jp/dbenecon/search.jsp?MENU=1)
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