ECCJ/AOTS Philippines training course

ECCJ / AOTS Philippines training course

Philippines

Example-1: Power Reduction by Process Modification

Example 1: continued
Improvements:
	Jig with same material to keep machining accuracy in heat expansion Air-oil mist spray onto tool edge lubrication for coolant flow Optimum condition for machining --- tool edge form, cutting condition, etc. Improvement on casting design --- to reduce machining work Improvement on chip removal Intermittent blow of coolant Piping pressure loss reduction Minimizing of coolant pump motor capacity
Results:
	Semi dry process applied to 90% of machining line. Coolant volume reduced to 10% in semi dry process, and 16% on whole line. Power cost reduced to 25% in whole line.

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)

Energy conservation check item (factory, building)

Energy conservation measure for factories (Energy Conservation Guidebook for Factories 2003-3)
2 Check item for energy conservation measure for factories -1
3 Check item for energy conservation measure for factories -2
4 Check item for energy conservation measure for factories -3
5 Check item for energy conservation measure for factories -4
Energy conservation measure for buildings (Energy Conservation Guidebook for Buildings 2004-3)
6 Check item for energy conservation measure for buildings -1
7 Check item for energy conservation measure for buildings -2
8 Check item for energy conservation measure for buildings -3

Check item for energy conservation measure for factories -1

General administrative matter

Energy management system

Organization improvement, human resource development
Compatibility with environmental management
Energy conservation target, investment budget
Long- and medium-range plans
Adoption of official preferential treatment systems
State of implementation of energy conservation

State of implementation of measurement / recording; state of installation and employment of measuring instruments

State of maintenance, inspection of measuring instruments
State of implementation of periodic measurements and recording

State of facility and equipment maintenance

Periodic inspection, routine inspection
Repairing of leaks (water, air, steam)
Heat insulation, insulation
Facility and equipment cleaning (filter, strainer), etc.

Management of energy consumption
- State of keeping daily reports
- Daily consumption, daily load variation curves
- Monthly consumption, ratio to the consumption of the preceding year graphs
Energy unit consumption management for major products

Energy unit consumption versus delivery price
Energy unit consumption versus production amount

Environmental conservation related management

State of implementation of measured for reducing CO² emission
State of utilizing the Law for Promoting Energy Conservation and Recycling
State of LCA (Life Cycle Assessment)
Waste treatment: state of promotion of waste reduction, sorting and recycling
Wastewater treatment

Improvement of processes

Improvement of processes
Reviewal of the factory line
Realization of continuous operation, efficiency improvement

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