On average 38% of air losses are due to poor knowledge on how to design and optimise pneumatic systems
Developing a proactive approach
Taking short term actions to reduce leaks produces an immediate payback however it is reactive in nature and masks the underlying cause: a lack of the skills and knowledge to identify and tackle the problem.
Developing an understanding of the cost of leaks and the in house capability to proactively reduce them starts with being able to answer questions such as:
Why do i have a situation where leaks exist?
- Were they delivered as part of the machine when new and we didn't notice?
- Have they been there for a long time and we just ignored them?
- Is it a component problem?
- Is it an application / design problem?
- Have they been introduced by us over time?
We also need a good understanding why the issue has not been effectively tackled. Again this is often a issue of knowledge:
- No-one in the organisation knows the cost of air (industry benchmark is 1.5p/m3
- Process reliability is more important than energy spend
- Compressed air waste is invisible
- Compressed air leaks pose no immediate health and safety threat
- Lack of understanding on how to address energy saving issue
Using the I-D-E-A method to reduce energy costs
Festo are experienced in using the I-D-E-A methodology to develop bespoke programs to help clients to understand the causes and impact of energy losses and develop an effective capability to continuously reduce them. By using this model we ensure that any potential training is targeted at the real identified needs of the business and the resulting outcomes measured.
I = Investigation of the Real Needs of Customers
D = Develop the Knowledge
E = Engage the Participants
A = Apply the knowledge
L = Lean Results (optional project model)