Professional Documents
Culture Documents
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QCC Team member
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Responsibility of Team
Machine Supply Process
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Responsibility of Team
Machine Supply Process
- Heat exchange set of
-Chilled water temp
production process
is 6 8 o C.
- Air conditioning
system (AHU)
- Air conditioning
system in production - Buildings /
line and all office- Machines, Process
building
Responsibility of Team
Machine Supply Process
- Offices
- Air conditioning
- MCC control
system
room
> 2 Machine/Day
1-2 Machine/Day
Level
11 - 20 Day / M.
1 Machine/Day
21-30 Day / M.
1 - 10 Day / M.
Within Unit
Scores
2 4 Units
All Units
Scores 1 2 3 1 2 3 1 2 3
Motivation
-To optimize compressed air systems to meet the KPI. 8.0 M3 / Kw.
- Reduce energy loss from a compressed air than necessary.
- To use energy efficiently.
-To meet the company's policy to save power 2,500 Kw / Day.
-Working together as a team Skills and creativity to fix it.
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Explore current problems System Air Instrument.
The following table shows the efficiency of compressed air systems Air Instrument
UTILITY Department ( January - May 2015 ) .
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8
8.45
7.34 6.98
Target KPI.
6 6.50 6.25
4
-
January February March April May
Month
Performance Air Instrument Jan - May 2015 averaged 7.10 M3 / KW (KPI = 8 M3 / Kw)
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Introducing the principle of compressed air.
Minimum Check valve Oil Cooler
Air Inlet valve
Oil Filter
After Cooler
Screw
Oil Separator
Air Filter
Check Valve
Oil Return
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12
Target
Optimize Air Instrument of 7.1 M3 / Kw. A 8.0 M3 / Kw. According to KPI.
The front of the UT 2015, within a period of six months
( June 1 -30 Nov 2015 ) .
M3/Kw-Hr
8.2
7.8
7.6
8.0 Increase
7.4 M3/Kw-Hr 11.25% Target Derivation
KPI of Utility Department Year 2015
7.2
7
7.1
Target KPI of Air Instrument at 8.0 M3/kw
6.8
M3/Kw-Hr
6.6
Target
Actual
now
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Work Plan June November 2015
WHEN
WHAT HOW WHY WHO WHERE
Jun July Aug Sep Oct Nov
Division meeting
Problem selection Pareto graph Problem selection All members
room
Flow sensor Flow meter readings are Dirt The catch is that the
3
AI is not malfunction inaccurate . probe Flow.
based on
performance
KPI Machine running The wind farm produces Used effectively
not Unload enough decreased the lifespan . 4
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Cause proof 1
Flow Measuring the wind does all the work
Proving cause
Surveyed the AI Main air supply and installation of the wind measurement Flow Power division .
The results Prove the cause Found a pipe that delivers air to the nitrogen, 98 % without Flow Measuring wind , but Flow Measuring
wind from the production of nitrogen, 98 % only , and measurement results were calculated for Flow wind really so . inaccurate data
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Cause proof 2
Drain the wind has dropped
Proving cause Check the condition and operation of the Auto-drain systems, air tanks AI.
The results Auto-drain the air tank is the system Timer Drain every 5 minutes, 10 seconds that it takes
too long , the wind Drain off the excess .
Air Compressor Timer Drain
Air Dryer
Filter
Timer Drain
Drain
Responsibility : Mr.Weerasak, Mr.Pakin
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Cause proof 3
Dirt caught in the probe Flow Meter.
Proving cause Condition monitoring of air measurement equipment Flow dirty that clog up
the sensor or not . Calibrate the probe flow and compare with others .
The results There was no dirty when comparing the values obtained from the sensor Flow
is measured , it is similar
Flow Meter
Flow Meter
8.1 7.8
Pressure AI (Bar)
Increase
Efficiency of Adjustable Timer Drain and analyzed at
Air Drain the wind has dropped Adjust Timer Drain
the on - off right .
Instrument
Adjust air pressure at Set pressure compressors. Using air pressure adjustments.
higher process equipment Proper air Used to fit With applications
needs.
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Problem solving of cause 1
WHAT HOW WHERE WHY WHEN WHO
Fitting Flow Flow meter installed at nitrogen 98% . Flow of
Main Nitrogen In order to know Mr.
measurement and information that has already passed . 15-30
the precise wind Khunchit,
measurement Measurement differences with the calculation 98% Jul 15 Mr. Pakin
makes the KPI. increase data.
analysis .
Program Kalki Flow chart showing the measurement results after installing
measuring devices Flow.
Trend graph AI after install Flow Meter Daily report AI after install Flow Meter
Efficiency AI
9.39.39.39.3
10.0
7.4 7.5
7.17.17.36.86.96.97.17.17.27.1 7.37.47.37.3 7.5
7.5 7.6
7.5 7.4
8.0 6.96.7 6.56.4
5.9
6.0
4.0
2.0
0.0
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 21
Problem solving of cause 1
The installed measuring devices Flow has already started removing the probe Flow check out will be very
difficult. Because the air pressure 7 Bar can not stop the Air pressure will affect the Process. The wind and the sound of the
wind, the wind is gushing out of the pipe all the time. To assemble the pipe and back to a long and windy which makes rubber
Flow meter is defective lacking. Air leakage and subsequent The measurement may be inaccurate Making it very difficult to
operate. And may have an impact on the Process.
We produce special equipment "EASY FIT" Support to make it easy to disassemble and reassemble Flow meter
, reducing time and risk. To remove - Flow Meter and assembly works completed at this point . Can also be applied to the
Flow Sensor and the other as well.
Using
Equipment EASY FIT
EASY FIT
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23
Use of the "Easy Fit"
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24
Problem solving of cause 2
WHAT HOW WHERE WHY WHEN WHO
Air Compressor
Filter
Process
AI
Tank Can save energy
= Reduce 3 seconds / times ( 288 times / day) .
Timer Drain Table losing air hose 1/2 " to 8 Bar lose air pressure = 28.52 L / Sec.
= 28.52 x 3 = 85.56 L / Time x 288 Time / Day x 360 Day = 766,434.5 M3 / Year)
Drain
= 766,434 / 8 M3 / Kw = 95,804 Kw / Year.
= 95,804 x 3 Baht = 287,412 baht / year . (U$ 8,211) 25
Problem solving of cause 4
WHAT HOW WHERE WHY WHEN WHO
Adjust Using
To reduce the
air pressure Try adjusting the pressure Air Compressor load of the
The machinery 1-15 July Mr.Wutti,
Supply , down from 7.2 Bar at Utility compressor
to make 2015 Mr.Pakin
Suitable for to 7.0 Bar. Department into line with
usage
work
8.1 7.8
Can save energy from setting pressure
Energy consumption 11.10 kw./hr x 24 hr./day
= 266.40 Kw./day
Cost saving as 266.40 x 3 Baht
= 799.20 Baht/day
or = 287,712 Baht/year (U$ 8,210)
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Engineering Value
* Running Air compressor No.2 Pressure supply 2,640 m3/hr. @ 7.2 bar
To reduce power consumption by reduce pressure supply to 7.0 bar.
8.4
8.5
8.2
8.3
8.3
8 8
7.88 8.0 7.8
7.7 7.7
7.6
7.5
7.4 0
7.2
7 June July August September October
June-15 July-15 August-15 September-15 October-15 November-15 Month
VAG. M3/Kw The graph compares the results before and after activities QCC.
8.4 Increase 15.21%
8.2
8
7.8
7.6 The activities.
8.18
7.4
8.0
7.2
M3/Kw
Performance increased to 8.18 M3 / kw ,
6.8
7
7.1 M3/Kw
6.6
6.4 M3/Kw or 15.18 % . Target is 8.0 M3 / kw
Before Target After
282828
Indirect results (QCDSMEE)
Optimization of manufacturing wind Air Instrument.
Reduce energy and wind power totaling = 575,124 Baht / Year.
(U$ 16,432)
3
8.12 M3/ Kw.
2
AVG. Jan May 2016 Jun. Aug 2016 Sep 2016 Mar 2016 30
Air is Free
But. !! Compressed Air is not..
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