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Seven Steps to Energy Efficiency for Foundries

Sham H. Arjunwadkar, Meghana R. Ransing, Rajesh Ransing Orcid Logo

Foundry Management and Technology, Volume: 143, Issue: 3, Pages: 24 - 29

Swansea University Author: Rajesh Ransing Orcid Logo

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...

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Published in: Foundry Management and Technology
Published: 2015
Online Access: http://foundrymag.com/energy-efficiency
URI: https://cronfa.swan.ac.uk/Record/cronfa24998
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spelling 2021-08-05T15:47:06.7971119 v2 24998 2015-12-08 Seven Steps to Energy Efficiency for Foundries 0136f9a20abec3819b54088d9647c39f 0000-0003-4848-4545 Rajesh Ransing Rajesh Ransing true false 2015-12-08 MECH 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. Journal Article Foundry Management and Technology 143 3 24 29 Energy optimisation, Melting process, Iron Foundry, Six Sigma, 7Epsilon, In-process Quality Improvement, Energy 12 3 2015 2015-03-12 http://foundrymag.com/energy-efficiency COLLEGE NANME Mechanical Engineering COLLEGE CODE MECH Swansea University 2021-08-05T15:47:06.7971119 2015-12-08T18:18:12.9439511 Faculty of Science and Engineering School of Aerospace, Civil, Electrical, General and Mechanical Engineering - Mechanical Engineering Sham H. Arjunwadkar 1 Meghana R. Ransing 2 Rajesh Ransing 0000-0003-4848-4545 3 0024998-08122015182331.pdf Energy_saving_using_7Epsilon.pdf 2015-12-08T18:23:31.2630000 Output 1119366 application/pdf Author's Original true 2015-12-07T00:00:00.0000000 true
title Seven Steps to Energy Efficiency for Foundries
spellingShingle Seven Steps to Energy Efficiency for Foundries
Rajesh Ransing
title_short Seven Steps to Energy Efficiency for Foundries
title_full Seven Steps to Energy Efficiency for Foundries
title_fullStr Seven Steps to Energy Efficiency for Foundries
title_full_unstemmed Seven Steps to Energy Efficiency for Foundries
title_sort Seven Steps to Energy Efficiency for Foundries
author_id_str_mv 0136f9a20abec3819b54088d9647c39f
author_id_fullname_str_mv 0136f9a20abec3819b54088d9647c39f_***_Rajesh Ransing
author Rajesh Ransing
author2 Sham H. Arjunwadkar
Meghana R. Ransing
Rajesh Ransing
format Journal article
container_title Foundry Management and Technology
container_volume 143
container_issue 3
container_start_page 24
publishDate 2015
institution Swansea University
college_str Faculty of Science and Engineering
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hierarchy_top_id facultyofscienceandengineering
hierarchy_top_title Faculty of Science and Engineering
hierarchy_parent_id facultyofscienceandengineering
hierarchy_parent_title Faculty of Science and Engineering
department_str School of Aerospace, Civil, Electrical, General and Mechanical Engineering - Mechanical Engineering{{{_:::_}}}Faculty of Science and Engineering{{{_:::_}}}School of Aerospace, Civil, Electrical, General and Mechanical Engineering - Mechanical Engineering
url http://foundrymag.com/energy-efficiency
document_store_str 1
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description 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.
published_date 2015-03-12T03:29:43Z
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score 11.035655

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