Abstract
Abstract There is a significant gap between India’s energy production and its demand. Dependency on energy imports to meet the energy requirement affects the economic growth & overall development. The manufacturing sector consumes a substantial portion of the country’s energy but also holds considerable potential for reducing consumption. This paper presents a case study on an Indian tower manufacturing industry, aiming to achieve energy efficiency and sustainability in the galvanization process through the application of the statistical tool Design of Experiments (DOE). By systematic implementation of 22 factorial model of DOE, the study identified that the excessive zinc coating thickness is the major cause of energy consumption in hot-dip batch galvanization process (HDBGP). It was found that average LPG consumption is minimized at moderate coating thickness. Applying DOE resulted in a 38.67% reduction in LPG consumption when the zinc coating thickness was maintained at a moderate level in HDBGP. DOE provides a systematic mechanism based on experimental data to identify potential causes of problems and offers statistical validation of results. This research focuses on creating an energy-efficient production system and demonstrates the practical application of statistical tools and techniques to achieve sustainable competitive advantages. Highlights Experimental work using the Design of Experiments tool identified excessive zinc coating thickness as the primary cause of high energy consumption in the hot-dip batch galvanization process. Validation of optimized parameters showed that average energy consumption is minimized at moderate coating thickness, resulting in a 38.67% reduction in energy usage. Design of experiments tool provides a systematic mechanism based on experimental data to identify potential causes of problems and offers successful validation of results. Discussion While the significant reduction in LPG consumption enhances energy efficiency and sustainability, excess reduction in coating thickness may compromise the quality and durability of galvanized products, potentially leading to higher long-term costs for maintenance and replacements. Additionally, the focus on statistical tools like DOE alone could divert attention from exploring alternative potential energy-saving technologies and methods that might offer greater benefits. Therefore, it is also essential to consider the broader implications and potential limitations of various approaches in the quest for sustainability and competitive advantage suitable for the existing manufacturing setups. Graphical abstract
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