Chapter 1
Energy conservation should be considered before thinking about "what to change."
When we talk about energy saving, we might immediately think of things like upgrading to highly efficient equipment, introducing new control devices, or changing insulation materials.
Of course, equipment upgrades can also be an effective solution.
However, if you don't have a good grasp of the current situation, it becomes difficult to determine "what needs to be changed" and "what should be prioritized."
The first thing we need to confirm is, "What is happening right now?"
The starting point for improvement is not buying new equipment, but accurately understanding the current situation.
Step 1
Measure | First, quantify the current situation.
The first step is to measure the condition of the factory and equipment.
The important point here is not that "we should measure everything." It's about organizing the necessary information according to the theme you want to improve.
Temperature
Temperature
Check the temperature conditions of furnaces, piping, equipment surfaces, products, etc.
Time
Time change
It records temperature rise, stabilization, cooling, and the operating status of the equipment.
Distribution
Temperature distribution
Check if there are any temperature differences depending on the location.
Energy
Energy
We will check the usage status of electricity, gas, etc., in conjunction with the target equipment and process.
The objects and methods of measurement vary depending on process.
Measure the temperature
Record the status
Step 2
Understanding | Thinking about "what to change" based on data
Simply collecting data will not lead to energy savings.
The next step is to look at the measurement results and consider "what is happening."
| What has become clear | Thinking |
|---|---|
| Only certain locations have high temperatures. | Check the insulation, equipment structure, and heat dissipation conditions. |
| The temperature fluctuates depending on the time of day. | Check operating conditions, load, external environment, etc. |
| There is a difference between the set value and the measured value. | Check the sensor, installation, and control status. |
| The condition varies depending on the equipment. | Compare differences in equipment and operating conditions. |
| The situation changed before and after the improvement. | Check the impact on quality and energy. |
Instead of looking for "what's wrong," look for "what can be improved."
When you look at the data, you may find anomalies or problems.
However, you don't need to improve everything at once.
It is important to prioritize while considering factors such as the effectiveness of the improvements, the impact on quality, the implementation costs, and the ease of execution in the field.
Instead of starting with the biggest problem, you can also start with a place that offers a good balance between effectiveness and ease of execution.
Step 3
Change | execution countermeasures
Once the issues are identified, we move on to actual improvements.
Countermeasures do not necessarily have to be large-scale equipment upgrades.
Review the equipment
We will replace and improve aging equipment and inefficient facilities.
Reviewing insulation
We will check the insulation condition of furnaces, pipes, tanks, etc., and consider necessary countermeasures.
Review control.
We ensure that the necessary energy is used appropriately according to the temperature and equipment conditions.
Review operations
We will review operating conditions, waiting times, and equipment usage.
What's important isn't the countermeasure itself, but being able to explain, using data, why that countermeasure is being implemented.
Verify
Once it improves, measure it again.
Making improvements is not the end of the process.
We will measure again under the same conditions and compare the results to those before the improvement to see what has changed as a result of the countermeasures.
| Before | Record the temperature and equipment status before improvement. |
|---|---|
| Action | Improve equipment, insulation, control, and operation. |
| After | Measure the improved state from the same perspective. |
| Review | Compare quality, energy consumption, equipment condition, etc. |
If you don't get the results you expected, you can investigate other factors and try to improve again.
Energy conservation is not something that can be accomplished with a single measure, but rather an activity that involves repeated measurement and improvement.
Summary
Start with "Measure, Know, Change."
Throughout these six sessions, we've explored the topic of decarbonizing factories.
Episode 1
Why is it difficult?
The difficulty lies in optimizing energy efficiency while maintaining quality.
Episode 2
Intuition and experience
An approach that combines on-site knowledge with data.
Episode 3
Heat loss
Consider heat transfer and invisible losses.
Episode 4
Quality and energy saving
We aim to achieve compatibility through measurement and control.
Episode 5
Corporate Value
Consider the supply chain and the data that can explain it.
Episode 6
Practice
This leads to a process of improvement: measure, understand, and change.
There isn't one single answer that applies to all companies when it comes to decarbonizing factories.
That's why we first measure what's happening in our own factory, understand the situation, prioritize, and then make improvements.
Then, we'll check the results of the improvements once again.
Measure → Know → Change → Verify.
Building on these small cycles is one way to connect factory decarbonization to continuous improvement.
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
related
Learn more about energy saving and measurement.
Measure the temperature
Record, monitor, and control
Series complete
Decarbonizing factories starts with "understanding the current situation."
We measure temperature and equipment status, and understand the current situation from that data. From there, we determine the priority of improvements, and then reconfirm the situation after implementing the countermeasures.
To advance decarbonization, what should be measured at your factory, and how should it be recorded and monitored? Please see the specific measurement examples below.
