ECCJ / AOTS Malaysias training course

ECCJ / AOTS Malaysia training course

Malaysia

4. Introduction of excellent energy conservation cases
CIMX Corporation, Excellent Case in 2005, Awarded by the Director-General of the Agency for Natural Resources and Energy

4.1 Cut of wasted electricity by using classification and measurement system for electricity consumption
CIMX Corporation, Excellent Case in 2005, Awarded by the Director-General of the Agency for Natural Resources and Energy

(4) Problems and study

(4)-1 Stand-by electricity when machines are not used (consciousness of operators)
Electricity consumption had been known only at each factory until the problem was taken up. Even if machines were not used, the power supplies were left turned ON and stand-by electricity kept flowing wastefully. It had not been known how electricity was wasted and, therefore, how much was paid for wasteful consumption. Especially, when operators were busy or working overtime, they would leave the machines with the power switch turned on.
(4)-2 Waste of air compressors
After checking the electricity consumption in each hour, it was found that the increase of the consumption did not always correspond to the operation of machines which supply air. Even when it corresponded to the operation, electricity was consumed more than necessary. The reasons were as follows.
(a) Leakage due to aging of pipes.
(b) Request for air from machines which were not working (it was found that electric spark wire cutters periodically requested air even after finishing the process).
(c) Inconsistency between compressor and machine group (Piping was not made according to operative conditions, so when only one machine was started at night, a big compressor would start).
(4)-3 Characteristics of electric spark wire cutter
It was not designed to automatically turn off the power switch after finishing processing. So it kept wasting the stand-by electricity until operators turned off the switch.

(5) Contents of corrective measures

(5)-1 Stand-by electricity when machines are not used (consciousness of operators)
[1] The company installed electricity measurement devices to 100 electric machines, which are equivalent to 80% of electricity consumed in the company, and started to classify the electricity consumption into wasteful and useful using dedicated software.
[2] [3] (Omitted)
[4] The company clarified the divisions which were good at cutting the stand-by electricity and the division which were not comparing with the consumption in January, 2004 as the reference point and gave the information to each operator with their pay slip.
[5] The electricity fee thus saved was equally distributed to each operator as "energy conservation dividend". [6] As a result, this system was supported by employee's families and became encouragement for improvement activities.
(5) -2 Waste of compressors While checking the joints of pipes, old pipes were changed to new ones. As a result, air leakage from pipes was stopped, and air supply to machines which are not requesting air was minimized.
(5)-3 Mechanical characteristics of electric spark wire cutter The design was changed to the one that automatically cut the power supply after processing.

(6) Effect after corrective measures

8/8
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