Ford電費(fèi)節(jié)約sigma項(xiàng)目英文版

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、靜夜四無鄰鄰，荒居舊業(yè)業(yè)貧。。12月-2212月-22Wednesday,December7,202210、雨中黃葉樹樹，燈下白頭頭人。。22:01:5322:01:5322:0112/7/202210:01:53PM11、以我獨(dú)沈久久，愧君相見見頻。。12月-2222:01:5322:01Dec-2207-Dec-2212、故人人江海海別，，幾度度隔山山川。。。22:01:5322:01:5322:01Wednesday,December7,202213、乍見翻疑疑夢，相悲悲各問年。。。12月-2212月-2222:01:5322:01:53December7,202214、他鄉(xiāng)生白白發(fā)，舊國國見青山。。。07十二二月202210:01:53下下午22:01:5312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(dòng)動(dòng)出成成果，，工作作出財(cái)財(cái)富。。。2022/12/722:01:5322:01:5307December202217、做前前，能能夠環(huán)環(huán)視四四周；；做時(shí)時(shí)，你你只能能或者者最好好沿著著以腳腳為起起點(diǎn)的的射線線向前前。。。10:01:53下下午午10:01下下午22:01:5312月月-229、沒有失失敗，只只有暫時(shí)時(shí)停止成成功！。。12月-2212月-22Wednesday,December7,202210、很很多多事事情情努努力力了了未未必必有有結(jié)結(jié)果果，，但但是是不不努努力力卻卻什什么么改改變變也也沒沒有有。。。。22:01:5322:01:5322:0112/7/202210:01:53PM11、成功就是日日復(fù)一日那一一點(diǎn)點(diǎn)小小努努力的積累。。。12月-2222:01:5322:01Dec-2207-Dec-2212、世間成事事，不求其其絕對(duì)圓滿滿，留一份份不足，可可得無限完完美。。22:01:5322:01:5322:01Wednesday,December7,202213、不知香香積