Ford電費節(jié)約6sigma項目(英文版)(ppt 37頁)

1、Reduce Electric Power Cost Project #16,005Final ReportPAG Import, Inc.Reduce Electricity Consumption Project TeamTeam MembersProject ChampionMr. M. Fukui(AS/ Quality Development)Project MembersMs. K. Uemura(Process Owner HR/ Administration)Ms. Akiyama(AS/Quality Development)Mr. I. Takayama(FIN/ Info

2、rmation Technology)Mr. S. Ohno(FIN/Finance, Business Plan)Mr. N. Adachi (BB AS/ Quality Development)Problem Statement Much electric power is consumed at the PAGI/FJL office. The electric power cost is significantly influencing the profitability of the company. The electric power cost of the Kamiyach

3、o office (Headquarter) was $218,700 in 2002. This corresponds to $50 per employee per month.Purpose of the ProjectReduction of Electricity CostProject Scope Activities of the project will be limited to the whole Kamiyacho office (7/8/10/11F). Air-conditioning cost of the business hours (8:00-18:00/

4、weekdays) is included in the office rental cost (fixed). As we cannot reduce or control this cost, we do not include this in the scope of the project. The scope should be normal electric power cost and the air-conditioning cost of overtime hours.Basic Strategy of the ProjectvThe activities of the pr

5、oject should be coordinated with the activities for Volvo ISO14001. The project should be linked with the activities to protect environment and should not be perceived as mere cost reduction.vThe negative influence on the business environment of employees must be minimized.MeasurementElectricity Cos

6、t (Yen) / Electric Power Consumption (kwh) and Air-conditioning Cost for Extra HoursvMonthly consumption of electric power is notified through the monthly bill from the Shuwa Building office.vElectric power consumption and its cost are in a linear relationship. Air-conditioning cost for extra hours

7、is determined based on the length of operation (hours) and areas (# of blocks).Target Reduce the electricity cost of the Kamiyacho office by 20% from $218,700 to $162,100. Reduce A/C cost for extra hours by 20% also.VOC - How to Promote Employees Efforts in Saving Electricity Consumption Points to b

8、e considered when taking measuresvAlways remind people of saving/ Avoid being forgotten.vFailure of saving could cause some disadvantage on each employee.vMake everything simple/ Avoid complicated processes.vSaving could bring convenience/ improved efficiency (No inconvenience/ no problems in effici

9、ency).vSaving activity looks cool / trendy.vGive the impression that everyone participates.vEfforts of each person is essential for the total success.vSaving is along with the corporate policy.vEach person can contribute a lot/ Problems could occur if I do not save.vSaving effects can be confirmed c

10、learly / We can feel the effects.vBusiness achievements are evaluated by the saving effect.vNot a temporary project. Activities should be continued.The Process of Using (Wasting) ElectricityOffice lightsNeed to confirm whetherLeft ONcleaners turn OFF the lightsFaxwhen they finish cleaning or not.Tho

11、se used exclusively by a department.Reception lights11FLeft ONCopy machinesor7/8/10FLeft ONAir-conditioningExtra hoursMeeting rooms/ Executive rooms/ Storages(Could be declined by Shuwa at the moment)(incl. Air-conditioning)Private electricfansPCsUsed for businessPrintersOrThose used exclusively by

12、departments, groups, etc.(Early morning)Cleaners turnON(Night)The last personturns OFFBoot whencoming to officeRecord the timecoming to officeRecord the timeleaving office(When leaving)Turn OFFKept ONLeft ONLeft ONRequestAdministrationRequest ShuwaOperate air-conditionersCharge cost(Morning)The firs

13、t personturns On(Night)The last personturns Off(Morning)The first personturns ON(Night)The last personturns OFF(Early morning)Cleaners turnON(Night)Administrationturns OFF(Early morning)Cleaners turnON(Night)The last personturns OFFTurned ONwhen roomsare usedTurned OFFwhen usersleave roomsLeave ligh

14、tsONRequest ShuwadirectlyThe last person/next person turnOFFFeel hot andturn ONTurn offC&E DiagramDo not know theDo not know they haveHard to find switchesHard to find switcheslocation of the switchindependent switchesForget turning offFunctionFunctionKnowledgeKnowledgeCleaners do not knowAttent

15、ionthey should turn offDo not recognize thatOthersDo not recognize thatDo not recognize thatlights should be turned offthey should be turned offthey should be turned offDo not recognize thatRecognition/ ideathey should be turned offRecognition/ ideaRecognition/ ideaRecognition/ ideaLights controlled

16、Hard to operate locationwith other roomsEfficiencyEfficiencyof the switchDo not know leavingFacilityoffice lastTake long time toTake long time toFacilitiesSwitches not locatedreboot from OFFreboot from OFFAttention, etc.adequatelyRecognition/ ideaRecognition/ ideaRecognition/ ideaRecognition/ ideaDo

17、 not recognize that Do not recognize that Do not recognize high costDo not recognize that they should be turned offthey should be turned offof air-conditioning/ influence they should be turned offon environment Unique problem ofCompelled to comeWIN 98 (shut down)to office on holidaysDo not know disp

18、laysFunctionsand peripherals have switchesOthersTake long time toHard to operate locationreboot from OFFLights controlled byof the switchKnowledgeblocks (1/4 floor)AttentionAttentionFacilitiesSleep mode not takenFacilitiesForget turning offForget turning offLightsLights of theReceptionsExecutive roo

19、ms,Storages, meetingroomsPCsPrintersCopy machinesAir-conditioning(Extra hours)Private appliances(fans, etc.)Waste powers/ Leavelights ONC&E MatrixvLowering wattage (without influencing on the business environment) is important in this project. Each process input (areas of electricity consumption

20、 and appliances, such as lighting of office and PCs) should be evaluated according to this.vPoints mentioned in the VOC can be basically fulfilled equally by all the process inputs.vA rough estimate of power consumption shows that lighting of office and PCs are two major process inputs in lowering w

21、attage.vAs the most important process inputs are clear, we did not develop a C&E matrix for this project. MSA - Converting the Monthly Data (1) Monthly power consumption data is reported by the maintenance company of the building after reading the wattmeters. It has turned out that there are som

22、e problems for this data as mentioned below. We must adjust the data to compare the consumption of power of each month correctly. Tenants cannot check the meters by themselves at this building.vThe days of checking meters differ from month to month. The data of the dates of checking can be followed

23、to the past.vThe numbers of business days differ much from month to month.vThe majority of appliances are not used on weekends though some are used just like main frame computers. Therefore, consumption of power significantly differs between business days and holidays.Converting the Monthly Data (2)

24、vWe applied the multiple regression analysis on monthly power consumption (Y), the number of business days (X1) and the number of holidays (X2) in the past data. We estimated the relationship between power consumption and Xs the number of business days and holidays.vWe converted the consumption data

25、 by using this relationship to make correct comparison between months with different number of business days and holidays.vIt has turned out that the power consumption was fairly stable between October 2002 and the start of the project by the analysis of the converted past data.Regression Analysis：

26、KWH versus Work days, HolidaysThe regression equation isKWH = 14486 + 2929 Work days + 1627 HolidaysPredictor Coef SE Coef T PConstant 14486 12417 1.17 0.259Work day 2928.8 484.0 6.05 0.000Holidays 1627.1 362.8 4.48 0.000S = 3649 R-Sq = 69.0% R-Sq(adj) = 65.4%Analysis of VarianceSource DF SS MS F PR

27、egression 2 503844693 251922347 18.92 0.000Residual Error 17 226339999 13314118Total 19 730184693Source DF Seq SSWork day 1 236055862Holidays 1 267788831Unusual ObservationsObs Work day KWH Fit SE Fit Residual St Resid 5 17.0 95248 88682 1692 6566 2.03R 7 22.0 102631 95191 1134 7440 2.15RMonthly Ele

28、ctric Power Consumption (Number of Days Adjusted)8090100110120130140Jan-02Feb-02Mar-02Apr-02May-02Jun-02Jul-02Aug-02Sep-02Oct-02Nov-02Dec-02Jan-03Feb-03Mar-03Apr-03May-03Jun-03YOY(%)80,00082,00084,00086,00088,00090,00092,00094,00096,00098,000100,000KwhPower Consumption(Before Starting the Project) T

29、he power consumption of the four floors (Number of days adjusted) combined is shown below.Comparison with the previous year(%)Left columnConsumption(kwh)Right columnBasic Concept of Z Value/ DPMOvDefects for PC usages are defined as that PCs are ON after their users left office.vSome PCs, which are

30、kept ON to have data transmission with abroad are excluded from defects.vDefects for spaces with independent light switches are defined as that lights of spaces are ON while no one is using.Z Value/DPMO (Before Taking Measures)vZ values and DPMOs were measured for spaces with independent light switc

31、hes and PCs.The investigation were made for the spaces with independent switches on August 22 and 26 (average). That for PCs was made on September 19.Kept ON whi l e theyshoul d be OFFDPMOZ ValueSpaces withindependent light27.9%278,8460.59PC62.1%621,253-0.31Conclusion From the Results of the Investi

32、gationThe Reasons of High DPMOvGenerally speaking, employees do not think they should turn off switches of PC monitors. Many employees do not know that PC monitors have switches.vSome are not conscious that lights of spaces with independent switches such as meeting rooms should be turned off. Also,

33、light switches are generally so small that many do not notice their existence. FMEAProcess:Electric power consumptionFMEA team: Reduce Electric Power Prepared by: N. AdachiPage: 1 of 1Productin the Kamiyacho officeConsumption Project TeamResponsible: K. UemuraFMEA date: August 23, 2003(Rev)Results o

34、f actionsPotentialFailure modePotentialfailure effectsSEVPotential causesOCCCurrent controlsDETRPNActions RecommendedResponsibleActions TakenSEVOCCDETRPN1 AllDo not turn off/Left ONWaste electricpower10Do not recognize that theyshould be turned off (wouldinfluence environment) /No guidelines.10Calle

35、d attention by E-mails.5 500Develop saving electric power guide-lines/ penaltysystem (Based on the situation of departments) /Save Energy idea contest/ Posters/ Symbol marks/Contests for finding light left ON (public spaces)/Show electric power consumption with graphs/Appoint department leaders for

36、saving power/ Ask thebuilding office to turn off lights (if left ON).Uemura/Adachi2Meetingroom/Executiverooms/ PCsDo not turn off/Left ONWaste electricpower3Do not recognize that theyhave independentswitches.8Installed a label to the lightswitch of the smokingroom/ installed posters topromote turnin

37、g off lightson the wall of the smokingroom.5 120Highlight switches with fluorescent labels/ Highlightswitches with labels, which say Please turn off lights- Related to #5.Uemura/Adachi3Office lights/Computers/PrintersLeft ON even afterall employees leftofficeWaste electricpower3Do not know the locat

38、ion ofthe switch (But know thereis).10Installed labels on lightswitches, which show therelated department.8 240Attach maps to the switch board of lights.Adachi4 PCsLeft ON while noone is usingWaste electricpower6Saving energy mode nottaken.85 240Takayama5 AllDo not turn off/Left ONWaste electricpowe

39、r8Forget turning off.75 2806 Office lightsDo not turn off/Left ONWaste electricpower3Do not recognize leavingoffice last.510 150(Include in the guide-lines)Uemura/Adachi7 Office lightsExcessive facility/equipmentWaste electricpower1Do not recognize that theyare excessive.2The Administrationdepartmen

40、t is watchingcarefully.510Lower the wattage of bulbs/ Reduce the numbers oflamps where they are not in need.UemuraProcess step/Part numberMeasures Taken (1)vChecked ON-OFF of PCs before business hours and gave warning to users of PCs kept ON.vChecked ON-OFF of lights of spaces with independent light

41、 switches. Announced the results and asked employees to improve.vDeveloped and installed labels that highlight switches of spaces with independent light switches.vAttached maps of the areas covered by each switch to the switch board.vConducted a “Save Energy Idea Contest” and implemented some excell

42、ent ideas applied for it (47 ideas applied from 19 employees).vInformed all employees light switches that cover their offices and persons that are with the same switches (to ease turning off lights).vLowered the temperature of the hot-water supply (95-40C/ 203-104F). Stopped supply during weekends.v

43、Installed labels that show the power consumption of areas controlled by each switch (In money/ weight of CO2/ areas of forests required for absorbing CO2).vInstalled caution labels to PCs, which call attention for turning off when users leave office.Measures Taken (2)vDeveloped action guidelines for

44、 saving power cost. Delivered them to employees by an E-mail and uploaded them in the PAGI web-site.vAsked and enlightened employees to save power through various kinds of E-mails.vThe rule of extending the air-conditioning hours that the requests must go through the Administration department is str

45、ongly enforced.vShortened the length of air-conditioning hours during summer compared with the previous years (until 20:00-19:00).vDeveloped and posted posters that call for saving electric power.vDeveloped and announced the rule of turning on/ off the lights of the reception of 8th floor (consumes

46、high wattage).vInstalled electric bulbs with lower wattage for the reception of 8th floor (85W-65W).vRemoved some of fluorescent lights near windows.Measures Taken (3)vOutsourced checking and turning off switches of lights, printers and copy machines on every Saturday morning (Started on November 15

47、).vReplacing PCs with energy-saving models (300 units).vAdjusted existing PCs to energy saving mode (63 units).vHighlighted door knob and light switches of the smoking room with noctilucent tapes. The smoking room does not have windows. The room becomes dark if the lights are turned off. As the door

48、 and the light switch are far apart, it was difficult to find the door after turning off the light switch.Cost of The Measures TakenvOutsourcing cost to check and turn off light switches on Saturday costs $50 every month. However, the effect of the first trial is estimated more than $90.vThe cost of

49、 taking the measures of the project is only around $20 including those for labels and noctilucent tapes.DPMOvThe Z value and DPMO for leaving PCs and lights ON have been greatly improved.Kept ON whilethey should beOFFDPMOZ ValueDPMOZ ValueSpaces withindependent27.9%278,8460.59147,0591.05PC62.1%621,2

50、53-0.31185,7920.89After the measures were takenBefore the measures were takenThe investigation was made on November 20.FMEA After the Measures Were TakenProcess:Electric power consumptionFMEA team: Reduce Electric Power Prepared by: N. AdachiPage: 1 of 1Productin the Kamiyacho officeConsumption Proj

51、ect TeamResponsible: K. UemuraFMEA date: August 23, 2003(Rev)Results of actionsPotentialFailure modePotentialfailure effectsSEVPotential causesOCCCurrent controlsDETRPNActions RecommendedResponsibleActions TakenSEVOCCDETRPN1 AllDo not turn off/Left ONWaste electricpower10Do not recognize that theysh

52、ould be turned off (wouldinfluence environment) /No guidelines.10Called attention by E-mails.5 500Develop saving electric power guide-lines/ penaltysystem (Based on the situation of departments) /Save Energy idea contest/ Posters/ Symbol marks/Contests for finding light left ON (public spaces)/Show

53、electric power consumption with graphs/Appoint department leaders for saving power/ Ask thebuilding office to turn off lights (if left ON).Uemura/AdachiDevelop saving electric power guide-lines/ posters/Put up a notice of electric power consumption/Outsource turning off lights/ switches (those left

54、ON).8541602Meetingroom/Executiverooms/ PCsDo not turn off/Left ONWaste electricpower3Do not recognize that theyhave independentswitches.8Installed a label to the lightswitch of the smokingroom/ installed posters topromote turning off lightson the wall of the smokingroom.5 120Highlight switches with

55、fluorescent labels/ Highlightswitches with labels, which say Please turn off lights- Related to #5.Uemura/AdachiSaving electric power guide-lines/ highlight switchesby labels.343363Office lights/Computers/PrintersLeft ON even afterall employees leftofficeWaste electricpower3Do not know the location

56、ofthe switch (But know thereis).10Installed labels on lightswitches, which show therelated department.8 240Attach maps to the switch board of lights.AdachiDevelop saving electric power guide-lines/Attach maps to light switch boards/ Inform allemployees light switches that cover theiroffices.255504 P

57、CsLeft ON while noone is usingWaste electricpower6Saving energy mode nottaken.85 240TakayamaIntroduce new OS(XP/2000), which is designed forsaving energy/ Introduce newer PCs with improvedenergy consumption/ Develop saving electric powerguide-lines.635905 AllDo not turn off/Left ONWaste electricpowe

58、r8Forget turning off.75 280Check computers before business hours/ Givewarning to users of those left ON/ Install labels onmonitors, which ask turning off computers/ Highlightlight switches with labels.8351206 Office lightsDo not turn off/Left ONWaste electricpower3Do not recognize leavingoffice last

59、.510 150(Include in the guide-lines)Uemura/AdachiDevelop a guideline for saving electric power/Promote greeting when leaving office to let those whoremain know they should turn off lights.325307 Office lightsExcessive facility/equipmentWaste electricpower1Do not recognize that theyare excessive.2The

60、 Administrationdepartment is watchingcarefully.510Lower the wattage of bulbs/ Reduce the numbers oflamps where they are not in need.UemuraReplace high wattage bulbs with those of lowerwattage/ Reduce the number of fluorescent lampsnear windows/ Lower the temperature of waters inthe hot water supply system.1155