中小企业精益生产路径探析(中英文翻译).doc
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中小企业精益生产路径探析(中英文翻译).doc
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QuantifyingEnergySavingsfromLeanManufacturingProductivity
Therationalforclaimingenergysavingcomesfromcomparingthebaselineenergyustothepost-eventenergyuse.Inthebaselinscenario,productionisincreasedbyaddinmanufacturingequipmentorbyextendinoperatinghours.Assuch,inthebaselinscenario,energyuseincreasesfromexistingusduetoadditionalequipmentoroperatinghours.
Alternately,inthepost-eventscenario,LeaManufacturingtechniquesenableproductiongainswithoutincreasingoperatinghoursoaddingmanufacturingequipment.Henceinthpost-eventscenario,energyuseisnotmucdifferentthatexistingenergyuse,andmuchlesthaninthebaselinescenario.
Currently,claimingenergysavingsfroproductivityimprovementsisnotwidespreadamongenergyefficiencyprogramsorLeaconsultants.Indeed,littlehasbeenpublishedohowenergysavingsshouldbequantifiedfrotheseimprovements.Inthispaperwepresentbriefreviewoftheexistingalgorithmsusedtcalculateenergysavingsfromproductivityimprovements.Furthermore,weproposetwnewapproachestocalculatingenergysavingeachwithexamples.
EXISTINGAPPROACHESTOCALCULATINGPRODUCTIVITYRELATEDENERGYSAVINGSDepartmentofEnergyIndustrialAssessmentCenters
TheDepartmentofEnergy’s(DOE)OfficeofEnergyEfficiencyandRenewableEnergy(EERE)IndustrialTechnologiesprogramsponsors26IndustrialAssessmentCenters(IAC)locatedatuniversitiesthroughoutthenation.TheIACsprovideenergy,wasteandproductivityassessmentsfreeofcosttoqualifyingsmallandmediumsizedmanufacturingfacilities.EachIACmustreportexpectedenergy,wasteandproductivitysavingsfromitsassessmentrecommendations.IACsmayclaim“effective”energysavingsfromproductivityrecommendations.Theapproachtocalculatingenergysavingsisbasedoncomparingpreand
post-implementationenergyintensityandmultiplyingthedifferencebypost-implementationproductionrates(Papadaratsakis,etal.,2003.).Whilethisapproachhasbeenpublishedindetail,wewillpresentanabbreviatedexamplehere.Forexample,aproductionprocesscurrentlyuses10kWh/unit.AfterimplementationofLeanManufacturingrecommendations,theprocessonlyuses8kWh/unit,andproductionhasbeenincreasedtofrom1,000to1,200units/year.Equation1presentstheeffectiveenergysavingsfromthisexample:
(1,200units/year)x(10–8)kWh/unit=2,400
Kissock(2005)oftheUniversityofDaytonIACdevelopedasimilarbutmoredetailedmethod.WhilePapadaratsakisetal.onlyconsideredunitizedenergyuse,Kissockdiscussedunitizedenergyuse(energyintensity)andnetenergyuse.Kissockalsousedinversemodelingofregressionmodelsbasedonrealdatatodeterminetheunitizedenergyforproductionquantity-dependent,temperature-dependentandoperatinghoursdependentcomponentsofenergy
use.Kissockalsorecognizedtheinfluenceofproductdemandonenergysavings,showingdifferentnetandunitizedenergysavingsdependentwhetherproductionquantityactuallyincreasinglyornot.NortheastUtilitiesProcessReengineeringImprovementforManufacturingEfficiency(PRIME)NortheastUtilities(NU)sponsorsthePRIMEprogramthroughtwoofitsmemberutilities,ConnecticutLight&Power(CL&P)andWesternMassachusettsElectricCompany(WMECO).ThePRIMEprogramissolelyfocusedonproductivityimprovementtoachieveenergysavings.LeanManufacturingconsultantsarecontractedtoprovidethreetofourday“Leanevents”.AstheLeanconsultantsdonotnecessarilyhaveenergyefficiencyexpertise,energysavingsarecalculatedwithageneralizedalgorithm.TheNUsavingsalgorithmreliesonasmallnumberofeasilyobtainedandunderstandableinputs,whichinfluencesavingscalculationsandwillvarysignificantlyfromsitetosite.Otherfactorsthatarenoteasilyobtainedmaybetimelierandcostlyassessmenttocalculate,maynotvarysignificantly,andarethussubstitutedwithgenericassumptions.NU’salgorithmrequiresthefollowinginputs:
1.Annualplant-wideelectricityuse
2.Percentaffectedelectricityuse:
ManyofthePRIMEeventsdonottargettheentiremanufacturingfacility,butperhapsjustoneproductionline.Assuch,determininghowmuchofthetotalannualelectricityuseisattributabletotheproductionlinesinquestionisanimportantestimate,typicallybasedonproductionvaluesorsales.
3.Pre-andpost-eventproductionquantity.Inadditiontothesethreeinputs,standardassumptionsappliedtoeachsiteinclude:
1.10-yearmeasurelife:
Thisvalueisusedtoonvertannualsavingsasdeterminedbythesavingsalgorithmtolifetimesavings.2.85%/10%/5%energydistributionassumption:
Thesavingsalgorithmassumesthatoftheaffectedelectricityuse,5%isattributabletoequipmentwithnoclaimablesavings.10%ofelectricityisattributedtoopera
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- 中小企业 生产 路径 探析 中英文 翻译