Takane Misawa1 Masao Yanagimori2 Satoru Isobe3
Mercian Corporation has established an environmental load management system at its Yatsushiro Factory by using Yokogawa's Enerize factory energy management system. The system is intended to manage data not only on energy consumption but also on the environment relating to production activities such as the amount of water consumed in the factory. This paper describes the successful introduction of this system.
As a company that has strong relationship with nature and provides products using nature's blessings, Mercian Corporation is committed to the environment. Its environmental philosophy is "Mercian thanks nature's blessings and capability that sustain life, and seeks to balance environmental preservation with creating an affluent society." To create a sustainable society, the company strives to conserve resources and energy, develop environment-friendly products, disclose information regarding environmental impact, and comply with laws. This paper describes the environmental load management system which was established at Yatsushiro Factory, one of Mercian's largest production bases, with Yokogawa's Enerize factory energy management system for factories.
Mercian recognizes that business activities inevitably impact on the environmental load. To fulfill its responsibility for maintaining the environment and creating a sustainable society, the company has set the following mid-term targets, based on its philosophy and management policy on the environment1.
Target 1: Reducing CO2 emissions caused by energy consumption
Factories: Reducing emissions by 7% in FY2012 compared with FY2002
Logistics: Reducing emissions below those in FY2004
Target 2: Reducing the use of water for manufacturing
Reducing usage by 20% in FY2012 compared with FY2002
Target 3: Reducing waste
Reducing the amount below that in FY2004
Target 4: Reducing the emissions of substances designated in the pollutant release and transfer register (PRTR) system
Reducing the emissions to 1/5 of those in FY2002 in FY2012
Target 5: Reducing the environmental load caused by containers and wrappings for liquors
Reducing their weight per capacity below those in FY2002
When building the environmental load management system, we concentrated on the management and reduction of CO2 emissions (target 1) and water for manufacturing (target 2) among these targets.
Table 1 shows the CO2 emissions and use of water for manufacturing by each production base in FY20081. The CO2 emissions due to energy consumption and use of water across the company increased by 3.6% and 6.5%, respectively, compared with FY2002. As shown in the table, Yatsushiro Factor y, which is the target of the management system, produces various items and thus emits more CO2 and uses more water than other factories. Therefore, we put priority on these reductions in the factory than in other factories.
Table 1 CO2 emissions and use of water for manufacturing by each production base
|Production base||Main products||CO2 emission [t]||Use of water for manufacturing [kt]|
|Tomakomai factory||Cattle feed||4,766||15|
|Nikko factory||Rice wine, seasonings, drug products, others||4,665||487|
|Fujisawa factory||Wine, others||6,579||237|
|Iwata factory||Medicine and chemicals||6,394||1227|
|Uwajima factory||Fishery feed||1,087||10|
|Yatsushiro Factory||Shochu (Japanese distilled clear liquor), medicine, chemicals, others||92,292||6,789|
Figure 1 Previous Flow of Operations from Collecting to Announcing Environmental Data
Issues in Yatsushiro Factory
Targets in Solving the Problems
To solve the problems and improve the efficiency, we set the following targets for the new system.
To solve the problems on the site and encourage the PDCA cycle to be carried out, it is necessary to identify inefficient areas of the factory. To do this, it is necessary to visualize the site timely, define key performance indicators (KPI) which shows the status of products and production lines and can be used for decision making, and manage them based on the indicators. As the Indicators (KPI), we have adopted the energy consumption per each product by production line and facility. We decided to measure the indicators, set new targets of the indicators utilizing the measured values, and build an environment to support the daily PDCA cycle.
To achieve the goals, we built an environmental load management system at the Yatsushiro Factory based on Yokogawa's Enerize factory energy management system.
Procedures to Build the System
Figure 2 outlines the flow to build the system.
|Figure 2 Outline of the flow to build the system|
The detailed procedures to build the system are as follows.
|Figure 3 Energy flow|
|Figure 4 Definition of organization, allocation data, and allocation ratio|
Total System Configuration
Figure 5 shows the system configuration and other systems.
Figure 5 Total System Configuration
Yokogawa's CENTUM CS3000 and TriFellow are used for the boiler control system and power relating facilities monitoring system. PLCs are used to control and monitor the electricity relating facilities and production facilities in the factory. These systems, PLCs and Enerize are connected through the OLE for process control (OPC) interface, and Enerize collects data periodically.
Data is sent to client PCs via a Web server. To ensure security, it is preferable to build an independent LAN between client PCs and the Web server, as well as between the Web server and data collecting systems such as Enerize. However, constructing a LAN over a wide area would require major work, so we compromised to use the existing in-house LAN and built a virtual local area network (VLAN) by installing routers for restricting unauthorized access to areas that need strict security. To do this, we worked closely with Mercian's in-house information service department.
Mercian's original per unit production management system and Enerize are connected through the file interface. The system accumulates and manages the information for energy per unit production generated by Enerize based on information such as manufacturing items, production lines, production quantities, and start and completion times of each manufacturing lot.
Overview of System Functions
Figure 6 System Functions and Flow of the Data
Figure 6 shows the functions of the environmental load management system and the flow of the data. The main functions are summarized below.
The results and expected effects of these activities are as follows.
Companies must comply with increasing management requirements such as the Revised Energy Saving Act, ISO14000, and ISO50001. Moreover, they need to respond to the carbon footprint system that requires marking for CO2 emissions. Thus, the circumstance of companies' environment- oriented management is becoming more severe. We expect this approach in Yatsushiro Factory can be deployed to other Mercian's manufacturing bases, thus promoting beneficial environmental management throughout the company.
Released in 1998, CENTUM CS 3000 R3 was Yokogawa's first integrated production control system to feature an HMI running on the Windows OS. Thousands of these systems are in use around the world, in a wide variety of industries. CENTUM CS 3000 R3 is interoperable with both CENTUM VP and CENTUM CS systems, which makes it possible for users to upgrade to a newer system with minimum investment
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