Ford电费节约sigma项目英文

ReduceElectricPowerCostProject

#16,005

FinalReportPAGImport,Inc.ReduceElectricityConsumptionProjectTeamJanuary7,2004TeamMembersProjectChampion

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)

HR:HR&Administrationdivision／AS:AftersalesBusinessDivision／FIN:Finance DivisionProblemStatement

MuchelectricpowerisconsumedatthePAGI/FJLoffice.Theelectricpowercostissignificantlyinfluencingtheprofitabilityofthecompany.TheelectricpowercostoftheKamiyachooffice(Headquarter)was$218,700in2002.Thiscorrespondsto$50peremployeepermonth.PurposeoftheProjectReductionofElectricityCostProjectScopeActivitiesoftheprojectwillbelimitedtothewholeKamiyachooffice(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).TargetReducetheelectricitycostoftheKamiyachoofficeby20%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、静夜夜四无无邻，，荒居居旧业业贫。。。2022/12/72022/12/7Wednesday,December7,202210、雨中黄叶叶树，灯下下白头人。。。2022/12/72022/12/72022/12/712/7/202210:01:51PM11、以我独沈沈久，愧君君相见频。。。2022/12/72022/12/72022/12/7Dec-2207-Dec-2212、故人江海别别，几度隔山山川。。2022/12/72022/12/72022/12/7Wednesday,December7,202213、乍见翻疑梦梦，相悲各问问年。。2022/12/72022/12/72022/12/72022/12/712/7/202214、他乡生白发发，旧国见青青山。。07十二月月20222022/12/72022/12/72022/12/715、比不了了得就不不比，得得不到的的就不要要。。。。十二月222022/12/72022/12/72022/12/712/7/202216、行动出出成果，，工作出出财富。。。2022/12/72022/12/707December202217、做前前，能能够环环视四四周；；做时时，你你只能能或者者最好好沿着着以脚脚为起起点的的射线线向前前。。。2022/12/72022/12/72022/12/72022/12/79、没有失败败，只有暂暂时停止成成功！。2022/12/72022/12/7Wednesday,December7,202210、很多事情情努力了未未必有结果果，但是不不努力却什什么改变也也没有。。。2022/12/72022/12/72022/12/712/7/202210:01:51PM11、成成功功就就是是日日复复一一日日那那一一点点点点小小小小努努力力的的积积累累。。。。2022/12/72022/12/72022/12/7Dec-2207-Dec-2212、世世间间成成事事，，不不求求其其绝绝对对圆圆满满，，留留一一份份不不足足，，可可得得无无