ECCJ / AOTS Malaysia training course

Malaysia

Energy Conservation Improvements

Case Presentation Activity of ECCJ 2
Participation on Case Presentation Activity 3
Examples of Improvements
Example 1:Power Reduction by Process Modification 4
Example 2: Dust Removal System in Foundry 6
Example 3: Manufacturing process improvement --- Eliminating heating process 7
Small Group Improvement Approaches 8
Case Presentation Meeting 9

Case Presentation Activity of ECCJ Energy Conservation Improvements by Groups of Plant Operators

ECCJ invites actual energy conservation cases through activities by small groups of plant operators and holds presentation meetings.
ECCJ has held presentation meetings each year since 1976. Participation in or attendance at the meeting and materials are free of charge.
Cases with great success are given prizes (57 cases in 2004 F.Y.)

Participation on Case Presentation Activity

The graphs are developed on the assumption that a change in air ratio does not affect the exhaust gas temperature.

Example-1: Power Reduction by Process Modification

Example 1: continued

Example 2: Dust Removal System in Foundry

Example 3: Manufacturing process improvement --- Eliminating heating process

Factory: Car parts --- alternator stator manufacturing process

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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