Chapter 1
Why do temperature conditions affect quality?
In the manufacturing process, temperature can affect the state of materials, chemical reactions, and the final product finish.
For example, in heat treatment, the desired properties are obtained by heating and cooling the material under specified conditions.
Temperature is controlled as one of process conditions in processes such as resin molding, chemical processes, and food manufacturing.
The important point is that you can't simply assume that "the higher the temperature, the better the quality" or "lowering the temperature saves energy."
The required conditions vary depending on the product, materials, equipment, and process.
Chapter 2
Why is "margin" allowed in manufacturing sites?
When determining manufacturing conditions, various fluctuations must be taken into consideration on-site.
Equipment variations
Even with the same settings, the actual temperature may vary depending on the equipment's condition and location.
Temperature unevenness
It's not guaranteed that every part of the furnace or equipment will reach the exact same temperature.
Changes in load
The way the temperature changes can vary depending on the quantity, placement, and input conditions of the product.
external environment
Ambient temperature, outside air, and door opening/closing may affect the condition of the equipment.
Because of these fluctuations, a certain margin of error is sometimes incorporated into the conditions at the site to ensure stable quality.
The problem is not having "leeway."
You shouldn't unnecessarily cut back on the margins necessary to maintain quality.
What we need to re-examine is whether we've confirmed whether that buffer is truly necessary with our current equipment and process.
Chapter 3
Measurement reveals the "actual state".
To consider ways to save energy, we need to look at what's actually happening, rather than just the set values.
| Confirm | What we can understand |
|---|---|
| Measure multiple points inside the furnace. | Temperature distribution and temperature unevenness depending on location |
| Record the change in time. | Conditions such as rising temperature, stabilization, and cooling. |
| Measure near the product | Difference between display values on the equipment and the actual items being processed. |
| Compare under different conditions | The effect of changes in operating conditions on temperature conditions |
| Record the before and after of the improvement. | How did the situation change as a result of the countermeasures? |
For example, if you only look at a single measurement for the entire furnace, you may not be able to understand the temperature differences between locations.
By checking temperature and time changes at multiple locations, we gain more information to consider "what conditions are necessary to maintain quality."
The amount of energy savings that can be achieved is not automatically determined by measurement.
Measurement is a means of increasing the information available for making decisions that consider both quality and energy.
Chapter 4
It's important not only to "measure" but also to "stabilize" it.
Even if the actual temperature conditions are known, if the temperature fluctuates significantly, it becomes necessary to allow for a margin of error in the conditions to stabilize the quality.
This is where temperature control becomes crucial.
Category
Measure
Determine the current temperature.
Compare
compare
Check the difference between the target value and the current value.
Control
Adjust
Adjust the output to heaters, etc.
Stabilize
stabilize
Maintain the required temperature.
Rather than raising the temperature unnecessarily, maintain the desired state as stably as possible.
This way of thinking is an important perspective for achieving both quality and energy efficiency.
Learn more about temperature control
Review the furnace temperature.
Chapter 5
Once improvements are made, the results will also be measured.
Even after implementing energy-saving measures, it's important not to stop at "it seems to have worked."
After changing the conditions, we check the temperature distribution, changes over time, and quality status, and compare them to the state before the improvement.
| Before | Measure and record the condition before improvement. |
|---|---|
| Change | Review insulation, control, and operating conditions. |
| After | Measure the improved state from the same perspective. |
| Compare | Compare quality, temperature conditions, energy usage, etc. |
This makes it easier to verify whether the countermeasures were truly effective and whether there was any impact on quality.
Measure → Change → Measure again.
This iterative process makes it easier to implement energy conservation measures not as a one-off initiative, but as a continuous improvement activity.
Next episode
Energy conservation is not just a matter for inside factories.
Reducing energy waste while maintaining quality is not just about reducing electricity costs and fuel consumption at the factory.
How was the product made, and what level of environmental load was incurred in that process?
This kind of information is a topic that needs to be considered throughout the entire supply chain.
In Episode 5, under the theme of "Low Carbon is a New Brand Value," we will consider factory decarbonization from the perspective of trade and competitiveness.
Series
Factory decarbonization series
Episodes 1 to 3
Episodes 4 to 6
- Episode 4: The Balance Between Quality and Energy Saving
- Episode 5: Low Carbon is a New Brand Value
- Episode 6: Energy-Saving Measures That Won't Fail
Previous / Next
Continue reading the series
In Episode 3, we considered the "escape routes" for heat in factories. In Episode 5, we will broaden our perspective beyond the factory and consider the relationship between decarbonization and businesses/supply chains.
