IHI Corporation
At the Aioi Works of IHI Corporation (hereafter "IHI"), the plant that supports the heavy industry group's Resources, Energy and Environment business area, an air leak inspection service and an air leak visualization camera were introduced as part of the plant's CO2 emission visualization activities. We spoke with Mr. Imada of the Manufacturing Technology Group, Manufacturing Department, Aioi Works, CSSBU, Resources, Energy & Environment Business Area, about how the introduction came about, the results achieved, and the plant's future energy-saving initiatives.
Q. Could you tell us about your business?
At IHI Aioi Works (hereafter "Aioi"), we manufacture boilers and tanks (LNG, ammonia) for thermal power generation. We also manufacture methanation equipment and more, under a mission to contribute to a decarbonized, circular society as an indispensable production base for a carbon-neutral society, backed by our manufacturing capability.
Q. What prompted you to adopt our products?
At Aioi, we had worked on energy visualization twice in the past.
The first time was in 2019. Based on the summary tables and energy flow diagrams we created when setting management standards under the Energy Conservation Act, we identified the energy used by each piece of equipment, converted it to crude oil equivalent, plotted it as a pie chart, and visualized it in order of largest energy use.
Across Aioi as a whole, we were able to visualize the electricity and fuel used by just under 30% of our equipment. As a result, however, we did not see the reduction we had initially hoped for.
I see. So the first attempt turned out a little differently from what you had expected.
The second time was in 2022. Led by the Advanced Information Management Division, we introduced PUSHLOG and power meters to visualize energy in the cloud, and were able to cover 90% of the equipment in the main building.
We also introduced the BI tool Tableau, and we analyze and chart the data we collect. On this tool we can check wasted electricity and unit costs by week, or narrowed down to any period we want to review. Basically we look at the gap between operating hours and electricity consumption, and if power is being consumed during hours when operating time is zero, clicking that part of the graph shows which machine is consuming the electricity.
So you can see wasted power consumption at a glance.
Yes. Being able to see the waste led to realizations, and in some cases it grew into an initiative for the entire plant.
We charted the data gathered in Tableau and put it on a cool-looking monitor so that anyone in the plant can see it. An ordinary monitor would do the job, but this one carries our logo and has a special feel to it, so we think it stands out more and leaves a stronger impression. By standing out, it catches more people's eyes, and we hope that increases the number of realizations as well.
Visualizing the data showed us that compressor usage was high. When we checked with the manufacturing manager, we realized that the rule of shutting down the compressors on holidays when the plant is stopped had not taken hold. That led us to look again at wasted compressed air in the plant. We consulted the supplier we work with, learned that air leak inspection existed, and went ahead with it.
Q. What results did you see from the air leak inspection?
The air leak inspection found 131 leaks in total, with a result showing a loss cost of 1,368,621 yen per year. Even before the inspection we had an activity called "air patrol," walking the plant to point out leaking spots and correct them immediately, but finding this many leaks even so was significant.
With the cooperation of everyone in the plant section, we were able to carry out corrective work on 115 of the 131 leaks found by the inspection (87.8%). Since the loss cost was 1,368,621 yen per year, that works out to a simple calculation of 1,201,649 yen per year saved. When it is presented to you as an amount of money like that, it becomes a trigger that raises your antennae for all kinds of initiatives. We received many suggestions from people on the floor and from managers as well. In particular, it led to an initiative where we listed why standby power could not be cut, identified which standby power was actually necessary, and cut the power in places where it was not.
Q. Please tell us how you came to introduce the air leak visualization camera after the inspection.
A large number of leaks were found during the inspection, and it was difficult to pinpoint the locations from the mapping in the report alone, so we decided to purchase an air leak visualization camera. When purchasing it, we already knew the loss amount from the air leak inspection results, so we could grasp the cost-effectiveness right away.
Q. What results have you seen since introducing the air leak visualization camera?
As a result of the air leak measures and standby power measures, when we compared electricity charges for fiscal 2022 and fiscal 2023, we achieved a reduction of 5.6 million yen per year even after accounting for the difference in operating hours. Also, after purchasing the air leak visualization camera, we lent the unit out around five times within the team leaders' meeting, and 50 new leaks were identified at Aioi. I had heard before that when you repair an air leak, a new one appears somewhere else, so I expect it to be a cat-and-mouse game for a while.
Fifty new leaks — that is a lot. As you say, once you repair one, pressure shifts to other places and new leaks appear. We also handle products designed to keep leaks from occurring in the first place, so please do give them a try.
Q. By the way, the word "realization" came up many times during this interview. Is it a theme for you?
It is a word I use often. First you have to realize the current situation and the issues, and from there: conceive, plan, execute, verify — and then realize something again. I think that cycle is extremely important.
So realizing is what gets things started.
Q. Finally, are there any energy-saving initiatives you are working on besides air leaks?
The big one is replacing transformers. On top of that, we have switched fluorescent lights that used to stay on all night to motion-sensor LEDs. They are small activities, but I think saving energy is also about gradually changing the way we think, so I would be glad if this prompts people to do something of their own.
Thank you very much for making time for us in your busy schedule today.
It was a truly valuable session in which we discussed not only solving air leaks but also energy saving and how to approach one's work. With "realization" as our keyword, we at AirMore will face air leaks with even greater commitment.