Journal article 1569 views 610 downloads
Seven Steps to Energy Efficiency for Foundries
Sham H. Arjunwadkar,
Meghana R. Ransing,
Rajesh Ransing 
Foundry Management and Technology, Volume: 143, Issue: 3, Pages: 24 - 29
Swansea University Author:
Rajesh Ransing
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Abstract
Steve Robinsons of American Foundrymen Society has once argued that foundries with 4% profit margin need to find new sales revenue of US$1 Million to generate US$40,000 operating profits. The case study presented in this paper highlights how an in-process quality improvement exercise resulted in ann...
| Published in: | Foundry Management and Technology |
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| Published: |
2015
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| Online Access: |
http://foundrymag.com/energy-efficiency |
| URI: | https://cronfa.swan.ac.uk/Record/cronfa24998 |
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| Abstract: |
Steve Robinsons of American Foundrymen Society has once argued that foundries with 4% profit margin need to find new sales revenue of US$1 Million to generate US$40,000 operating profits. The case study presented in this paper highlights how an in-process quality improvement exercise resulted in annual saving of US$144,000 by studying in-process data in a melt room on 25 process inputs. Foundry is an energy intensive industry. Energy costs for foundries are around 15% of the cost of castings. In recent years foundries have become energy aware and many have installed energy meters with on-line energy monitoring systems to report energy consumption (kWh) per tonne, charge or furnace with varying sampling frequency. This paper highlights how 7 Steps of 7Epsilon were implemented and in-process data for a foundry was visualised using penalty matrices to discover energy saving opportunities. With ISO 9001:2015 on the horizon there is an urgent need to change the foundry culture - across the world - towards capturing, storing, reusing in-process data as well as organisational knowledge in order to demonstrate in-process quality improvement. The 7Epsilon approach offers a structured methodology for organizational knowledge management as well as in-process quality improvement. |
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| Keywords: |
Energy optimisation, Melting process, Iron Foundry, Six Sigma, 7Epsilon, In-process Quality Improvement, Energy |
| College: |
Faculty of Science and Engineering |
| Issue: |
3 |
| Start Page: |
24 |
| End Page: |
29 |