For Global PA Project Team,

Energy Management Solution by

May 23-24, 2011 Mitsubishi Electric Nagoya Works

COPYRIGHT 2010 MITSUBISHI ELECTRIC CORPORATION ALL RIGHTS RESERVERD. BEP-8129-280

P-1

 Whats e&eco-F@ctory?

+ Energy Saving

Solution which enables visualization of shop floor with IT system to reduce production cost

Solution which enables visualization of production and energy saving to reduce production cost and energy cost

COPYRIGHT 2010 MITSUBISHI ELECTRIC CORPORATION ALL RIGHTS RESERVERD. BEP-8129-280

P-2

Overview of e -F@ctory e-F@ctory

e-F@ctory is the Mitsubishi FA total solution, which realizes improvement in productivity and efficiency, and cost reduction by utilizing data in real-time. FA-IT connectivity products

(Manufacturing Execution Systems)

MITSUBISHI MITSUBISHI FA FA Products Products FA Components Field Network Engineering Environment

PLC

CNC

EDM Laser Robot processing machine

Servo

Inverter

COPYRIGHT 2010 MITSUBISHI ELECTRIC CORPORATION ALL RIGHTS RESERVERD. BEP-8129-280

P-3

Configuration of conventional information systems

Challenges of interlinking information between systems

Information Systems
Quality Control, Process Control Functions, etc.

Need for gateway computers Need for communication software development Incapable of real-time analysis

Control system/ controller

Mitsubishi FA Product Groups

net Ether

COPYRIGHT 2010 MITSUBISHI ELECTRIC CORPORATION ALL RIGHTS RESERVERD. BEP-8129-280

P-4

Configuration of information system using MES interface

Information Systems
Quality Control, Process Control Functions, etc.

Direct connection with database through MES Interface Control system/ controller
Mitsubishi FA Product Groups

net Ether

COPYRIGHT 2010 MITSUBISHI ELECTRIC CORPORATION ALL RIGHTS RESERVERD. BEP-8129-280

P-5

MES Interface Functions

Directly connects controllers with Database of information systems, so communication gateway systems are NOT needed.
Information system MES application Database Information system MES application Database

Information linkage

Host information system communication processing Data processing (operation processing, logging, etc.)

SQL data transport

Controller communication
Polling processing Gateway PC

Communication module PLC (CPU)

MES Interface module PLC, GOT

COPYRIGHT 2010 MITSUBISHI ELECTRIC CORPORATION ALL RIGHTS RESERVERD. BEP-8129-280

P-6

e-F@ctory production line in Nagoya

Stator Production Line
Winding wire Welding Midterm test Mold

Rotor Production Line

Magnet Rotor Balancing application assembly

Oracle Oracle Database Database

Viewer Viewer

Winding condition etc

Welding time etc

Winding wire Resistance value etc

Mold condition etc Operation information jigs and tools information etc

Adhesion condition etc

Dimension accuracy etc

Remaining Unbalance quantity etc

SQL SQL message message Web Web service service

Result etc Accuracy etc Result etc Result etc

Magnet Adhesion condition etc

Bolt tightening torque etc

Assembly accuracy etc

Average resistance value etc

Quality Analysis tool (QC tool)

Accuracy Resistance Pressure Magnetizing Assembly measurement test test

Encoder assembly

Encoder test

Shipping test

Quality Assurance Section Line monitor

Motor Assembly Line

Flow of products Production process MELSEC sequencer
<MES interface installed>

Worker

Quality Information Operation information Instruction Information

Control Supervisor Engineering Leader Facility operation analysis tool Technical Production Section Engineering Section

COPYRIGHT 2010 MITSUBISHI ELECTRIC CORPORATION ALL RIGHTS RESERVERD. BEP-8129-280

P-7

 How to save energy

0 Current After

0
1

Visualization of energy by measurement Install energy meters Energy saving by high efficient devices Replace with high efficient devices

Waste Productivity

1
2

3 3

Energy saving by improving the operation Find energy waste by managing the power consumption rate [KPI] 3 3 Energy saving by production improvement Improve the productivity

COPYRIGHT 2010 MITSUBISHI ELECTRIC CORPORATION ALL RIGHTS RESERVERD. BEP-8129-280

P-8

 Energy saving by improving the productivity Improvement of Productivity = Energy Saving

Point Countermeasure
- Reduce idle time of machine Reduce Switching time Reduce no parts time Optimize the production schedule - Reduce the down time of machine Preventive maintenance System - High performance machine Introduce of the highperformance IA product - Improve quality rate Reduce human error Introduce of static approach

Point

Improvemen t of machine availability

Energy Saving by reducing waste on machines

Energy Saving Side

Productivity Side

Improvemen t of the throughput Minimize the loss of quality

Energy Saving by shorten the operation time Energy Saving by reducing time for rework

COPYRIGHT 2010 MITSUBISHI ELECTRIC CORPORATION ALL RIGHTS RESERVERD. BEP-8129-280

P-9

Visualization of Electric energyMeasuring by measurement 2. Mitsubishi Products

Q-Series Power Measurement Module (NEW!)

Reduce wiring and space: Module mounted directly on the MELSEC-Q base unit High-speed sampling to obtain accurate measurement: Current, voltage, power, power factor, and effective power Obtain data without the need of PLC programs Visual GOT screens 1) Measurement for each machine Precise energy control per product unit 2) Real time measurement Effective preventive maintenance 3) Linked with manufacturing information Easy quality control

COPYRIGHT 2010 MITSUBISHI ELECTRIC CORPORATION ALL RIGHTS RESERVERD. BEP-8129-280

P - 10

Visualization of energy by measurement Example of Nagoya works Heating Oil Utility Gas
0
0.4% LP-GAS 6.1% 3.2% Improve Productivity Heavy Oil 0.3%

Proportion of electricity usage

Electricity 90%

Production Line 33%

Air Conditioning 40%

Office 18.5% 18.5%

Compressor Lighting 9% 15% High Efficient devices Factory 81.5% 81.5%

Proportion of electricity usage in factory

Improve the loss of the operation

usage by purposes Proportion of energy

COPYRIGHT 2010 MITSUBISHI ELECTRIC CORPORATION ALL RIGHTS RESERVERD. BEP-8129-280

P - 11

Energy saving by High Efficient Devices

The loss of power distribution High Efficient Transformer The loss of Air conditioning VFD The loss of Compressor VFD The loss of motor/pump/fan IPM motor/VFD

Super High Efficient Transformer

VFD

IPM motor
High Efficiency Motor

Eco drive

Compared to standard product

Compared to no VFD

Compared to standard Compared to standard motor product

60

Reduce the loss

Realize energy saving

60

25

Reduce the loss

10

more efficient
P - 12

COPYRIGHT 2010 MITSUBISHI ELECTRIC CORPORATION ALL RIGHTS RESERVERD. BEP-8129-280

Energy saving by High Efficient Devices New Drive Technology applied to Kani factory
Result of using IPM Motor
Condition for installation Result of the following operation for 1 year Energy Cost 14yen/kWh
Air Volume 100 80 60

Time(hour) 0 7 8 9 12 13 17 18 20

Result

IPM Motor Usage

Applied Machine Air Handling Machine Air Handling Machine Air Handling Machine Air Conditioner Rated Power 1.5kW 3.7kW 7.5kW 1.5kW Installation 2 2 4 36

How much could we reduce the cost?

Power Power Consumption Consumption 541,348 541,348 378,472 378,472 kWh kWh /Year /Year Energy Energy Cost Cost $75K $75K $52K $52K USD]/Year USD]/Year CO Emission CO2 2 Emission 300.4 300.4 210.1 210.1 ton ton /Year /Year
CO2 Emission 1,000kWh0.555ton-CO2 P - 13

Drive ModuleFR-FP500J Fan is droved by belting.

COPYRIGHT 2010 MITSUBISHI ELECTRIC CORPORATION ALL RIGHTS RESERVERD. BEP-8129-280

Energy saving by managing Power Consumption Rate

Daily/Weekly Graph for Power consumption rate

Weekly Weekly graph graph

Power consumption rate = [kWh/number of unit]

Daily Daily graph graph

Power Power consumption consumption rate rate got worse got worse -> -> Productivity Productivity decreased decreased Production Production is is lower lower with withrespect respect to to the the energy energy consumption consumption

Measured Measured Power Power consumption consumption rate rate helps helps us us detect detect the the wasted wasted energy energy and and grasp grasp the the productivity productivity with with respect respect to to the the energy energy consumption consumption
COPYRIGHT 2010 MITSUBISHI ELECTRIC CORPORATION ALL RIGHTS RESERVERD. BEP-8129-280

P - 14

Energy saving by managing Power Consumption Rate Our approach: Utility cost Production Line
Sept. Sept. of of 2008 2008 SEC SEC = = 2.4kWh 2.4kWh
Production Line Air Conditioner Machine Tools 40% 33% Compressor Lighting 9% 15% Utility

25 Reduction based on SEC

Air Conditioner 26%

Dec. Dec. of of 2008 2008 SEC SEC = = 1.8 1.8 kWh kWh

Machine Tool Lighting 46% 13% Compressor 11%

Improve the operation Clean-up heat exchange 4.3%

Optimize the pressure of compressor 0.8% Air Compressor with IPM

Air Conditioner with VFD Re-layout of lightings 5.4% Lighting with VFD

Electric Transformer

Energy Saving in utilities

Energy Saving in production lines

P - 15

COPYRIGHT 2010 MITSUBISHI ELECTRIC CORPORATION ALL RIGHTS RESERVERD. BEP-8129-280

Energy saving by managing Power Consumption Rate

Floor Level
EMU2-CT5 CD-40ANA PD-100KFH

To Reduce Energy Waste

Add to Database e-F@ctory

Power Data

Application to check energy per unit

EcoMonitor Pro

Energy Save Products

Floor Level
MDU

Production Data

- Production Volume - Start / End time - Product name

Power Data Add MES Interface

- Power - Period - Equipment

EcoMonitor Pro

Alarm when energy consumption increase

COPYRIGHT 2010 MITSUBISHI ELECTRIC CORPORATION ALL RIGHTS RESERVERD. BEP-8129-280

P - 16

Energy Saving by improving the productivity Reducing the down time

e-F@ctory History of machine failure (Down time) Database Application No parts 10%

Down time

48%

4% 6% 2% 2% 10% 52% 22%

Up time

52%

Switch of machine parameter 22%

2%

Categorized by reason History of machine failure Machine Faiulre Operation time, Machine Status
MES Interface

(Down timeReason)

Status, Down time per each machine

Machine to attach magnet

Short down time can be detected

COPYRIGHT 2010 MITSUBISHI ELECTRIC CORPORATION ALL RIGHTS RESERVERD. BEP-8129-280

P - 17

3 3

Investigation and analysis from the machine failures conditions Prioritized Countermeasures (Sorted by frequencies)
Conditions Frequency Countermeasures

Upper line conveyor 2 Cycle error

Adjust theConditions conveyor guide/ Modify the software Frequency Washing robot internal error Magnet attachment error on the Occurs at the improvement of conveyor tray -> Complete the jig adjustment Washing robot Cycle error

Countermeasures Enable retry after failure: Set the robot down for reattachment Enable retry at workpieces inconsistency and extend the time until the error notice Acceptance value is +/-3% Let the operators check the measured value when the error occurs

<Servo amplifier> Excessive error

Application ST2 Cycle error Entrance shutter Cycle error Magnet transfer 2 Magnet error at attachment position

Adjust the conveyor level/ Modify the software Measurement 1: Measured value is illegal

Measurement 2: Measured value is Magnet stopped at the magnet centering section illegal -> Execute chamfering as an interim measure to cut the interfering section Rotation lock 1 Return/Cancel Additionally cut the interfering section of the part

Magnet transfer forwardbackward return/exit

Magnet transferring palette 2 Prevent the operator's failure A part came off the UV unit Cycle error -> Install the part, additionally tighten the other parts, and eliminate the interfering section The cable around the hand is intercepting the light to Robot controller error the area sensor -> Check the cable treatment Instruct the operation Magnet supply tip 1 Up/Down Magnet attachment error at pickup pos. Application robot error

In-situ return impossible

Execute quick exhausting to reduce the effect from back pressure Correct the difference of magnet length Turn the magnet in the tray right-side up

COPYRIGHT 2010 MITSUBISHI ELECTRIC CORPORATION ALL RIGHTS RESERVERD. BEP-8129-280

P - 18

3 3

Result Reducing down time to improve the productivity will contributes energy saving

Line-G Trend

Cycle Error Magnet error at attachment position

Redu
Down Time (Hours)

ce do wn ti me

COPYRIGHT 2010 MITSUBISHI ELECTRIC CORPORATION ALL RIGHTS RESERVERD. BEP-8129-280

P - 19

Thank you!!

COPYRIGHT 2010 MITSUBISHI ELECTRIC CORPORATION ALL RIGHTS RESERVERD. BEP-8129-280

P - 20