Ford電費節(jié)約sigma項目

ReduceElectricPowerCostProject

#16,005

FinalReportPAGImport,Inc.ReduceElectricityConsumptionProjectTeamTeamMembersProjectChampion

Mr.M.Fukui (AS/QualityDevelopment)ProjectMembers Ms.K.Uemura (ProcessOwner–HR/Administration) Ms.Akiyama (AS/QualityDevelopment) Mr.I.Takayama (FIN/InformationTechnology) Mr.S.Ohno (FIN/Finance,BusinessPlan) Mr.N.Adachi (BB–AS/QualityDevelopment)

ProblemStatementMuchelectricpowerisconsumedatthePAGI/FJLoffice.Theelectricpowercostissignificantlyinfluencingtheprofitabilityofthecompany.TheelectricpowercostoftheKamiyachooffice(Headquarter)was$218,700in2002.Thiscorrespondsto$50peremployeepermonth.PurposeoftheProjectReductionofElectricityCostProjectScope

ActivitiesoftheprojectwillbelimitedtothewholeKamiyachooffice(7/8/10/11F).Air-conditioningcostofthebusinesshours(8:00-18:00/weekdays)isincludedintheofficerentalcost(fixed).Aswecannotreduceorcontrolthiscost,wedonotincludethisinthescopeoftheproject.Thescopeshouldbenormalelectricpowercostandtheair-conditioningcostofovertimehours.BasicStrategyoftheProjectTheactivitiesoftheprojectshouldbecoordinatedwiththeactivitiesforVolvoISO14001.Theprojectshouldbelinkedwiththeactivitiestoprotectenvironmentandshouldnotbeperceivedasmerecostreduction.Thenegativeinfluenceonthebusinessenvironmentofemployeesmustbeminimized.MeasurementElectricityCost(Yen)/ElectricPowerConsumption(kwh)andAir-conditioningCostforExtraHoursMonthlyconsumptionofelectricpowerisnotifiedthroughthemonthlybillfromtheShuwaBuildingoffice.Electricpowerconsumptionanditscostareinalinearrelationship.Air-conditioningcostforextrahoursisdeterminedbasedonthelengthofoperation(hours)andareas(#ofblocks).Target

ReducetheelectricitycostoftheKamiyachoofficeby20%from$218,700to$162,100.ReduceA/Ccostforextrahoursby20%also.VOC-HowtoPromoteEmployees’EffortsinSavingElectricityConsumption–PointstobeconsideredwhentakingmeasuresAlwaysremindpeopleofsaving/Avoidbeingforgotten.Failureofsavingcouldcausesomedisadvantageoneachemployee.Makeeverythingsimple/Avoidcomplicatedprocesses.Savingcouldbringconvenience/improvedefficiency(Noinconvenience/noproblemsinefficiency).Savingactivitylookscool/trendy.Givetheimpressionthateveryoneparticipates.Effortsofeachpersonisessentialforthetotalsuccess.Savingisalongwiththecorporatepolicy.Eachpersoncancontributealot/ProblemscouldoccurifIdonotsave.Savingeffectscanbeconfirmedclearly/Wecanfeeltheeffects.Businessachievementsareevaluatedbythesavingeffect.Notatemporaryproject.Activitiesshouldbecontinued.TheProcessofUsing(Wasting)ElectricityC&EDiagramC&EMatrixLoweringwattage(withoutinfluencingonthebusinessenvironment)isimportantinthisproject.Eachprocessinput(areasofelectricityconsumptionandappliances,suchaslightingofofficeandPCs)shouldbeevaluatedaccordingtothis.PointsmentionedintheVOCcanbebasicallyfulfilledequallybyalltheprocessinputs.AroughestimateofpowerconsumptionshowsthatlightingofofficeandPCsaretwomajorprocessinputsinloweringwattage.Asthemostimportantprocessinputsareclear,wedidnotdevelopaC&Ematrixforthisproject.MSA-ConvertingtheMonthlyData(1)Monthlypowerconsumptiondataisreportedbythemaintenancecompanyofthebuildingafterreadingthewattmeters.Ithasturnedoutthattherearesomeproblemsforthisdataasmentionedbelow.Wemustadjustthedatatocomparetheconsumptionofpowerofeachmonthcorrectly.Tenantscannotcheckthemetersbythemselvesatthisbuilding.Thedaysofcheckingmetersdifferfrommonthtomonth.Thedataofthedatesofcheckingcanbefollowedtothepast.Thenumbersofbusinessdaysdiffermuchfrommonthtomonth.Themajorityofappliancesarenotusedonweekendsthoughsomeareusedjustlikemainframecomputers.Therefore,consumptionofpowersignificantlydiffersbetweenbusinessdaysandholidays.ConvertingtheMonthlyData(2)Weappliedthemultipleregressionanalysisonmonthlypowerconsumption(Y),thenumberofbusinessdays(X1)andthenumberofholidays(X2)inthepastdata.WeestimatedtherelationshipbetweenpowerconsumptionandXs––thenumberofbusinessdaysandholidays.Weconvertedtheconsumptiondatabyusingthisrelationshiptomakecorrectcomparisonbetweenmonthswithdifferentnumberofbusinessdaysandholidays.IthasturnedoutthatthepowerconsumptionwasfairlystablebetweenOctober2002andthestartoftheprojectbytheanalysisoftheconvertedpastdata.RegressionAnalysis：KWHversusWorkdays,HolidaysTheregressionequationisKWH=14486+2929Workdays+1627HolidaysPredictorCoefSECoefTPConstan170.259Workday2928.8484.06.050.000Holidays1627.1362.84.480.000S=3649R-Sq=69.0%R-Sq(adj)=65.4%AnalysisofVarianceSourceDFSSMSFPRegression250384469325192234718.920.000ResidualError1722633999913314118Total19730184693SourceDFSeqSSWorkday1236055862Holidays1267788831UnusualObservationsObsWorkdayKWHFitSEFitResidualStResid517.09524888682169265662.03R722.010263195191113474402.15RPowerConsumption(BeforeStartingtheProject)Thepowerconsumptionofthefourfloors(Numberofdaysadjusted)combinedisshownbelow.Comparisonwiththepreviousyear(%)－LeftcolumnConsumption(kwh)－RightcolumnBasicConceptofZValue/DPMO<PCsandSpacesWithIndependentLightSwitches>DefectsforPCusagesaredefinedasthatPCsareONaftertheirusersleftoffice.SomePCs,whicharekeptONtohavedatatransmissionwithabroadareexcludedfromdefects.DefectsforspaceswithindependentlightswitchesaredefinedasthatlightsofspacesareONwhilenooneisusing.ZValue/DPMO(BeforeTakingMeasures)ZvaluesandDPMOsweremeasuredforspaceswithindependentlightswitchesandPCs.TheinvestigationweremadeforthespaceswithindependentswitchesonAugust22and26(average).ThatforPCswasmadeonSeptember19.ConclusionFromtheResultsoftheInvestigationTheReasonsofHighDPMOGenerallyspeaking,employeesdonotthinktheyshouldturnoffswitchesofPCmonitors.ManyemployeesdonotknowthatPCmonitorshaveswitches.Somearenotconsciousthatlightsofspaceswithindependentswitchessuchasmeetingroomsshouldbeturnedoff.Also,lightswitchesaregenerallysosmallthatmanydonotnoticetheirexistence.FMEAMeasuresTaken(1)CheckedON-OFFofPCsbeforebusinesshoursandgavewarningtousersofPCskeptON.CheckedON-OFFoflightsofspaceswithindependentlightswitches.Announcedtheresultsandaskedemployeestoimprove.Developedandinstalledlabelsthathighlightswitchesofspaceswithindependentlightswitches.Attachedmapsoftheareascoveredbyeachswitchtotheswitchboard.Conducteda““SaveEnergyIdeaContest”andimplementedsomeexcellentideasappliedforit(47ideasappliedfrom19employees).Informedallemployeeslightswitchesthatcovertheirofficesandpersonsthatarewiththesameswitches(toeaseturningofflights).Loweredthetemperatureofthehot-watersupply(95->40C/203->104F).Stoppedsupplyduringweekends.Installedlabelsthatshowthepowerconsumptionofareascontrolledbyeachswitch(Inmoney/weightofCO2/areasofforestsrequiredforabsorbingCO2).InstalledcautionlabelstoPCs,whichcallattentionforturningoffwhenusersleaveoffice.MeasuresTaken(2)Developedactionguidelinesforsavingpowercost.DeliveredthemtoemployeesbyanE-mailanduploadedtheminthePAGIweb-site.AskedandenlightenedemployeestosavepowerthroughvariouskindsofE-mails.Theruleofextendingtheair-conditioninghoursthattherequestsmustgothroughtheAdministrationdepartmentisstronglyenforced.Shortenedthelengthofair-conditioninghoursduringsummercomparedwiththepreviousyears(until20:00->19:00).Developedandpostedpostersthatcallforsavingelectricpower.Developedandannouncedtheruleofturningon/offthelightsofthereceptionof8thfloor(consumeshighwattage).Installedelectricbulbswithlowerwattageforthereceptionof8thfloor(85W->65W).Removedsomeoffluorescentlightsnearwindows.MeasuresTaken(3)Outsourcedcheckingandturningoffswitchesoflights,printersandcopymachinesoneverySaturdaymorning(StartedonNovember15).ReplacingPCswithenergy-savingmodels(300units).AdjustedexistingPCstoenergysavingmode(63units).Highlighteddoorknobandlightswitchesofthesmokingroomwithnoctilucenttapes.Thesmokingroomdoesnothavewindows.Theroombecomesdarkifthelightsareturnedoff.Asthedoorandthelightswitcharefarapart,itwasdifficulttofindthedoorafterturningoffthelightswitch.CostofTheMeasuresTakenOutsourcingcosttocheckandturnofflightswitchesonSaturdaycosts$50everymonth.However,theeffectofthefirsttrialisestimatedmorethan$90.Thecostoftakingthemeasuresoftheprojectisonlyaround$20includingthoseforlabelsandnoctilucenttapes.DPMOTheZvalueandDPMOforleavingPCsandlightsONhavebeengreatlyimproved.TheinvestigationwasmadeonNovember20.FMEA––AftertheMeasuresWereTakenMinitabAnalysis––StatisticMeaningoftheImprovement(1)TheratioofPCsleftONdramaticallydecreasedafterthemeasuresweretaken.Theimprovementisstatisticallysignificant.TestandCIforTwoProportionsSampleX(OK-OFF)N(Total)Samplep1(Before)1393670.3787472(After)2983660.814208Estimateforp(1)-p(2):-0.43546195%CIforp(1)-p(2):(-0.499106,-0.371816)Testforp(1)-p(2)=0(vsnot=0):Z=-13.41P-Value=0.000MinitabAnalysis––StatisticMeaningoftheImprovement(2)ThemixofthespaceswithindependentlightswitchesleftONalsohasbeendramaticallydiminished.Theimprovementisstatisticallysignificant.TestandCIforTwoProportionsSampleXOK-OFF)N(Total)Samplep1(Before)751040.7211542(After)58680.852941Estimateforp(1)-p(2):-0.13178795%CIforp(1)-p(2):(-0.252260,-0.0113147)Testforp(1)-p(2)=0(vsnot=0):Z=-2.14P-Value=0.032PowerConsumption(Adjusted)––AllFloorsCombinedThestartoftheprojectYOY(%)－－LeftcolumnConsumption(KWH)––rightcolumnsCostofExtendingAir-conditioningHoursThecostofextendingair-conditioninghourshasbeendramaticallylowered.YOY(%)––RightcolumnConsumption(kwh)－－LeftcolumnEstimateoftheProfitabilityImprovementPowerconsumptionhasbeenloweredby9.4%fromthe’’02data(’’03August––Octoberaverage).Extensioncostofair-conditioninghourshasbeenreducedby50.9%(’’03August––Octoberaverage).Applyingthesereductionratiotothefullyearcostof’’02,wewouldgetthefollowingcostimprovement.Powercost：$16,970（Excludingfixedcharge/’02total:$180,600）Extensioncostofair-conditioning：$67,890（’02total:$133,400）Total：$84,860（27.0%ofthe’02total:$314,000）<$1=118.9Yen/#682:’’02––’05Average>+)Control-I-MRChart（’02Jan.～’03Oct.）TheprocesswillbecontrolledwithI-MRchartsforpowerconsumption(#ofdaysadjusted)andtheYOY%ofair-conditioningcostforextrahours.PowerConsumptionI-MRChartYOY%ofExtraAir-conditioningCostI-MRChartControlPlanControl–ProcessControlintheFutureThefollow-upmeetingwillbeheldsixmonthsaftertheprojectisclosed(around’04July).Whethertheimprovementiscontinuedwithoutproblemsandwhetherthereisanypotentialproblemsintheprocesswillbediscussed.Whethertheprocessisincontrolornotwillbejudgedeverymonth.Ifthereareanyproblems,causeswillbeimmediatelyinvestigatedandremedieswillbetaken.LongTermMSAAdjustingthenumberofdaysineachmonthwillbedoneusingtheconversionmethoddevelopedintheMeasurephase.However,thechangeintherelationshipintheweightofweekdaysandweekendscouldchangebecauseofthemeasurestakeninthisproject(motingturningofflightsonweekdayscouldraisetheweightofweekends).Checkingbasedonthenewdataafterthemeasuresweretakenwillalsobedone.ConclusionsTheprojecthassignificantlyreducedelectricpowerconsumption;however,thereductionisasfarasaround10%.However,asthereductionintheextensioncostofair-conditioninghoursissohugethatthecombinedreductionofpowerconsumptionandextensioncostofair-conditioninghourswellsurpassed20%.ManyofthemeasurestakenwillfullycontributeafterNovember(datanotknownyet).Moresavingeffectsbytheprojectisforeseen.Thiswouldbeconfirmedinthefollow-upmeeting.Theprojecthasbroughtexcellentoutcomes.ReplicatingtheProjectAllthemethodstakeninthisprojectcanbetakenalsoinotherfacilitiesinJapanandothermarkets(countries).9、靜夜四無無鄰，荒居居舊業(yè)貧。。。12月-2212月-22Wednesday,December7,202210、雨中黃葉葉樹，燈下下白頭人。。。22:01:4922:01:4922:0112/7/202210:01:49PM11、以我我獨沈沈久，，愧君君相見見頻。。。12月月-2222:01:4922:01Dec-2207-Dec-2212、故人江海海別，幾度度隔山川。。。22:01:4922:01:4922:01Wednesday,December7,202213、乍見翻翻疑夢，，相悲各各問年。。。12月-2212月-2222:01:4922:01:49December7,202214、他鄉(xiāng)鄉(xiāng)生白白發(fā)，，舊國國見青青山。。。07十十二二月202210:01:49下下午午22:01:4912月月-2215、比不了得就就不比，得不不到的就不要要。。。十二月2210:01下下午12月-2222:01December7,202216、行動出成果果，工作出財財富。。2022/12/722:01:4922:01:4907December202217、做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