5.4.3 Individual Activity Achievable
IAA =g IWH (12a) equal to the hours worked on average by each worker, being:
IWH working hours, corresponding to the hours of presence on the job determined by the collective agreement for the working period considered (average data that also considers the organization of shifts);
g maintenance labour efficiency (measured as indicated inSect. 4.1);
a absenteeism index, estimated by statistical data.
TheMaintenance Labour Requirement will be determined by:
MLR¼BMAVþPMAV IAA
5.5 General and Complementary Equipment
For the fluidic vectors considered ‘‘critical’’ from a safety point of view (compressed gas, inflammable or hazardous fluids) strict safety prescriptions must be applied.
Whenever production processes are energy consumption intensive, it is appropriate to set out some modern systems for monitoring, to allow the operators to adjust the process parameters requiring necessary specific maintenance intervention quickly.
In order of effect on transformation cost, we review the automotive production processes of high specific energy consumption level below:
• body in white painting;
• foundry for cast iron or light alloys;
• polymer transformation;
• steel cold stamping;
• metal machining;
• body in white welding and assembly.
Relative to the above processes, it is proper to adopt energy-saving tech- nological solutions. In particular, it is necessary to apply modern systems for heat generated from the recovery of transformation processes and for the recycling of rejected fluid and solid material.
Furthermore, it is to be underlined that conditioning necessary for solid func- tioning of some technological processes and occasionally for the needs of the working environment is a relevant part of energy consumption in automotive factories. Relative equipment must be well designed to optimize thermal flow and to be easily regulated while functioning, according to need.
Another point of attention concerns the lighting systems for the shop floor and the offices, which must be set considering energy-saving criteria as well as the systems mentioned earlier; this is to assure the necessary level of illumination in the working areas, distinguishing them from the transit areas, the warehouses and the other secondary areas, while respecting safety criteria. Lighting groups should be high performing, divided by sectors and regulated automatically by photo- electric cells with programmable thresholds.
In the future, more restrictive norms for energy-saving criteria and CO2 emission will be applied, so as to engage General Equipment Makers in devel- oping more sophisticated technological solutions.
5.5.2 Co-generation Equipment and Electric Energy Consumption Control Systems
At some automotive final assembly plants, where scale of economy and localized activity provide convenience, co-generation equipment for energy production (thermo-electric power stations nearby or inside the plant) are employed. In these
situations, steam generated from low pressure turbines can be directly used both for heating of the working environment and for technological use, especially for body painting processes. The economic advantage is more significant when these power stations are connected to public networks and can interact, absorbing energy when more is needed or providing energy when there is an excess. In the future, photoelectric panel application will be more common, so that solar power will be used for conditioning working environments.
To optimize energy consumption, it is important to have dedicated monitoring systems. Starting from data collecting in real time, weekly or monthly reports are organized to better focus countermeasures or improve necessary actions.
It is suitable to appoint a specific person responsible for ‘‘energy-saving’’
activities for each production plant, with whom all unit managers should collab- orate in general equipment management. Concentration of activities on certain working shifts, as well as considering the differences in energy fees, appropriate area sectioning, and modular equipment adoption, are all typical actions for lim- iting energy consumption.
From the moment that energy resources are ‘‘critical’’ by definition, it is appropriate to control equipment efficiency and plan necessary corrective actions. The analysis of final specific consumption allows for monthly moni- toring of deviations from standard utilization.
In this regard, it is important to consider that:
• in Italy, electric energy cost is higher than the average in EU countries, and even more if compared to North America or Eastern Europe;
• in other world areas with poor mineral resources, but where industrial activities are developing fast (such as Brazil or China), serious electrical energy shortages can occur periodically, as a consequence of sudden hydric lacks that can con- dition trends in production activity.
Let us conclude this section by underlining the importance of fire fighting systems that are included in the general equipment. Maintaining efficiency within these systems, according to risk prevention policies, is the responsibility of Plant Technical System Management.
5.5.3 Auxiliary Equipment and Exhaust Material Management
By auxiliary equipment, we mean:
1. equipment for technological fluid treatment and recirculation, such as lubricant and cooling liquid for metal printing and metal machining process, industrial water for body in white pre-treatment processes…;
2. equipment for collecting and recovering chips resulting from metal transfor- mation processes, such as foundry wastes, blanking and shearing chips…;
3. equipment for regeneration and exhaustion of solid and liquid materials resulting from transformation processes, such as sands and soil in foundry, lubricants and coolants, chemical products in the painting process;
4. equipment for decreasing dust and the depuration of gas resulting from metal and polymer transforming processes, chemical-physical treatments and surface coating and functional dynamic tests in cells for engines and vehicle.
The above types of auxiliary equipment are becoming more relevant from a technical and economic point of view, in relation to the more severe norm for internal and external environmental emissions. Managers and those responsible are in charge of assuring that these rules will be respected and that maintenance and control of this equipment will be done according to legal requirements.
Working costs for this equipment is principally due to the specific energy consumption and particularly expensive consumable materials, such as diaphragms for ionic exchangers and liquids for technical cleaning. As a consequence, the management of this equipment requires serious attention, both from a cost point of view and from a legal liability point of view.