Reducing Part Washer Electricity Consumption By 82% With GLSS
California
Manufacturing
Production
82%
- The problem: A manufacturing facility sought to address the excessive energy consumption of its part washer system. This project aimed to reduce operational inefficiencies and meet sustainability goals by optimizing the washer’s electricity usage.
- With GLSS Green Belt Training & Certification, the organization reduced energy waste by 82% while enhancing operational control.
Automate Project Work + Documentation with Kure
In the world of engineered materials, efficiency and sustainability are critical. Many industrial environments rely on various equipment that must run smoothly to support day-to-day operations. In this case, the inefficiencies of the part washer system were leading to inflated energy costs and unnecessary wear and tear on equipment. Since energy consumption is a major factor in the operational costs of these centers, improving the washer’s performance would make a significant impact. The organization realized that to remain competitive and environmentally responsible, process improvements were essential.
The part washer system was designed to run continuously whenever production was active, regardless of actual washing needs. This led to unnecessary energy consumption, as the washer remained on even during idle times. Shutting down the washer without halting the associated production equipment wasnât an option, which only worsened the energy inefficiency. For the organization, improving this system was crucial for reducing costs and supporting its sustainability initiatives.
To meet these challenges head-on, the organization chose GLSS Green Belt Training & Certification, seeking to implement effective changes that would optimize their system and drive meaningful results.
An in-depth analysis revealed that the core issue was with the existing programmable logic controller (PLC). The design didnât allow for the independent shutdown of the part washer, meaning it ran alongside production, even when it wasnât needed. This flaw was the key driver behind the excessive electricity consumption. In addition, operators lacked the tools necessary to intervene when the washer was running unnecessarily, further contributing to the energy waste.
To tackle the issue, the team implemented two key solutions:
- PLC Update: The Programmable Logic Controller (PLC) system was updated to allow the part washer to operate independently from the production line. This enabled operators to shut it down during times when washing wasnât required, drastically reducing the washer’s runtime.
- Manual Bypass Switch: A manual bypass switch was added to give operators control over the washer, enabling them to turn it off whenever necessary. This easy-to-use feature provided immediate energy savings without disrupting production.
The implementation started with a detailed analysis of the existing PLC system to identify necessary modifications. The engineering team then made the required updates, ensuring the part washer could be independently controlled.
Next, they installed the manual bypass switch, placing it in a location for easy operator access. To ensure a smooth transition, GLSS Training & Certification provided online hands-on problem-solving tools for the team, enabling them to maximize energy savings faster than expected.
The solutions implemented had an immediate impact. The part washer no longer needed to run continuously, and operational hours were reduced significantly from 22 hours to 4, dropping electricity consumption by 82%. In addition to cutting costs, the project helped lower the companyâs carbon footprint, contributing to its broader environmental objectives.
with GLSS
This successful project showcases how GLSS Green Belt Training & Certification‘s innovative instructional design and content drive quick and effective results. By updating the PLC and installing a manual bypass switch, the organization not only solved the immediate energy consumption issue but also positioned itself for future success. The collaboration with GLSS ensured that employees had the skills and knowledge needed to maintain these improvements, creating a path for continued operational excellence and sustainability.
*We value our clients’ confidentiality. While we’ve changed their names, the results are real.
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