Specific Examples
Improving Production Lines at Facility in Marugame, Kagawa Prefecture
Improving Processing Equipment for Punching Metal Plates using a Turret Punch Press (TPP)
Reviewing Unnecessary Line Operation
Reducing Energy Used when Errors Occurred during Unmanned Nighttime Operation.
In the past, main production lines automatically came to a halt when trouble occurred during unmanned nighttime operation, but hydraulic pumps and other equipment continued to operate. By making visible the amount of energy used by hydraulic pumps per unit produced, the waste of energy during non-production times became apparent. On the post-improvement line, automatic power switch-off functions were added to units that use substantial amounts of power, such as the hydraulic unit, chiller unit and scrap conveyor. Control units, however, remain powered to allow process recovery after the line restarts and make effective use of in-process materials. These improvements resulted in an annual savings of 70 MWh of electricity.
Revising Output Levels
Power Reduced after Reviewing Pressure Needed to Operate TPP Hydraulic Unit.
Previously, the maximum hydraulic pressure for punching units at TPP facilities was set to 45 tons (hydraulic pressure of 31 MPa). After reviewing the pressure required to handle various materials, thicknesses and dies, it was determined that punching operations could be handled adequately with a maximum pressure of 30 tons (hydraulic pressure of 25 MPa). Reducing this maximum power requirement saved 31 MWh per year.
Punching at a TPP facility
Saving Energy through a Change in Cooling Method
Power Consumption Reduced by Changing Air Conditioning from Two Chiller Units to One Cooling Tower.
Formerly, one chiller unit was used for each TPP line, similar to the setup used on room air conditioners, and these chiller units cooled the oil used on the lines. However, the aged chiller units were upgraded through conversion to a single cooling tower. This improvement saved approximately 221 MWh of electricity per year, as well as reducing the cost of upgrading equipment. This case study is a good example of how production line improvements can be made through a simple variation in approach.
