scholarly journals Key variable analysis and identification on energy consumption of automotive manufacturing plant

2016 ◽  
Author(s):  
Lujia Feng ◽  
Laine Mears ◽  
Jorg Schulte
Keyword(s):  
Energy Consumption ◽  
Manufacturing Plant ◽  
Automotive Manufacturing ◽  
Variable Analysis

scholarly journals Energy Consumption Modeling and Analyses in Automotive Manufacturing Plant

2016 ◽  
Vol 138 (10) ◽  
Author(s):  
Lujia Feng ◽  
Laine Mears
Keyword(s):  
Energy Consumption ◽  
Energy Modeling ◽  
Manufacturing Plant ◽  
Automotive Manufacturing ◽  
Manufacturing Plants ◽  
Modeling Approach ◽  
Paint Spray ◽  
World Energy ◽  
Spray Booth ◽  
Energy Consumption Modeling

Manufacturing plants energy consumption accounts for a large share in world energy usage. Energy consumption modeling and analyses are widely studied to understand how and where the energy is used inside of the plants. However, a systematic energy modeling approach is seldom studied to describe the holistic energy in the plants. Especially using layers of models to share information and guide the next step modeling is rarely studied. In this paper, a manufacturing system temporal and organizational framework was used to guide the systematic energy modeling approach. Various levels of models were established and tested in an automotive manufacturing plant to illustrate how the approach can be implemented. A detail paint spray booth air unit was described to demonstrate how to investigate the most sensitive variables in affecting energy consumption. While considering the current plant metering status, the proposed approach is advanced in information sharing and improvement suggestion determination.

scholarly journals Exploratory Study on Safety Climate in Malaysian Automotive Manufacturing

2014 ◽  
Vol 3 (2) ◽  
pp. 30-34 ◽  
Author(s):  
Nor Azma Rahlin ◽  
Nik Wan Omar ◽  
Abd Aziz Muda ◽  
Azizah Endut
Keyword(s):  
Correlation Analysis ◽  
Work Environment ◽  
Internal Consistency ◽  
Exploratory Study ◽  
Safety Climate ◽  
Pearson Correlation ◽  
Manufacturing Plant ◽  
Automotive Manufacturing ◽  
Two Factors ◽  
The Relationship

Safety climate scrutiny has been given attention by the organization in increasing productivity and efficiency in the workplace. The purpose of this study is to determine the relationship between safety climate construct factors and safety climate. Safety climate measurement as developed by Vinodkumar and Bashi was used and distributed to the selected respondents in the national automotive manufacturing plant. Internal consistency of six safety construct factors and correlation between safety construct factors and safety climate were validated using reliability analysis and Pearson correlation, respectively. The survey instrument scores had acceptable overall internal consistency (a = 0.913). The correlation analysis indicated that only two factors in safety construct factors have significant with safety climate. Both factors are enforcement of regulation and procedure of safety and safeness of work environment. The finding of this study provides a useful framework for the organization in practicing safety climate. DOI: http://dx.doi.org/10.3126/ijosh.v3i2.6101 

Simulation Based Studies of Energy Saving Measures in the Aluminum Tool and Die Casting Industry

2016 ◽  
Vol 856 ◽  
pp. 131-139 ◽  
Author(s):  
Matthias Henninger ◽  
Wolfgang Schlüter ◽  
Dominik Jeckle ◽  
Jörg Schmidt
Keyword(s):  
Energy Efficiency ◽  
Energy Consumption ◽  
High Temperature ◽  
Specific Energy ◽  
Flue Gas ◽  
Die Casting ◽  
Operation Mode ◽  
Specific Energy Consumption ◽  
Manufacturing Plant ◽  
Furnace Charge

This study, which focuses on analyzing aluminum melting and die casting procedures is part of the Smart Melting project in the research network Green Factory Bavaria (GFB). The aim of the present research project is to investigate these procedures and to suggest measures to increase the overall energy efficiency. The analysis starts with the capture of the operating structure, the relations between supply and consumption of liquid aluminum and an evaluation of aluminum furnaces themselves. The study concentrates on shaft furnaces whose specific energy consumption is 25 % higher than stated by the manufacturers. At the same time the melting capacity of the furnaces ranges at the lower end according to the manufacturer's data. The reason for this deviation is a discontinuous operation mode due to demand fluctuations. Consequently the flue gas has still a high temperature which means a high waste of energy. Based on these facts the furnace charge and operation mode have to be optimized and the high temperature flue gas can be used to preheat the pig aluminum.A numerical model of aluminum furnaces is applied to investigate this optimization potential. This model can simulate either a single aluminum furnace (case 1) or a furnace integrated in the entire manufacturing plant (case 2). The advantage of case 1 is the furnace's operation on its most efficient point because there is no influence of the die casting process. In case 1 an improvement of the furnace charge leads to a higher capacity utilization and therefore to a reduction of 30 % specific energy consumption and a 50 % increase of melting capacity. Whereas in case 2 the simulation of the entire manufacturing plant results in a rise of 25 % melting capacity and a 16 % decrease of specific energy consumption. The simulation proved increasing energy efficiency due to preheating the pig aluminum in both cases.

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