Energy Savings Through Applications of Lean Manufacturing Principles

Abstract

This study explores and investigates the applicability of lean manufacturing principles and concepts in Dual Purpose Water and Electricity (DPWE) production plants. An existing DPWE production plant in the State of Qatar was used as a case study. The aim of the investigation was to identify opportunities for energy savings by analyzing plant energy use through Lean Value Stream Mapping. To this end, lean principles were employed to investigate energy wastes in the power and water production chains. ‘Lean deadly wastes’ were used to identify potential ‘wastes’ along the DPWE production system. Tools and techniques for analyzing, evaluating, and assessing energy use in the DPWE production plant were developed. Areas of energy wastes along the process system were identified and lean concepts were applied to reveal quick, non-capital energy saving opportunities. Energy assessments were carried out through the value stream mapping method that helped in the identification and detection of energy and operating efficiency improvement opportunities. The multi-stage flash distillation process was identified as the section that consumed relatively the largest energy. Other energy efficiency opportunities were revealed by virtually reconfiguring the DPWE production plant in the framework of lean principles and concepts. Results of the case study shows that a number of energy saving opportunities and energy efficiency initiatives exist in the various sections of the DPWE production plant. Therefore, lean principles are powerful concepts that can help in identifying energy saving opportunities and energy efficiency initiatives in DPWE production plants. Such opportunities and initiatives can be implemented to improve operating efficiencies and reduce production costs with the added advantage of improved environmental performance.