Plant Evaluation Index for Operating Rate and Energy Use
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Solution Overview
Problem
Current plant evaluation methods struggle to simultaneously assess production effectiveness and energy efficiency, as Overall Equipment Effectiveness (OEE) primarily measures production effectiveness, while energy consumption rate measures energy efficiency, leading to a trade-off relationship that complicates optimal operation determination.
Innovation Solution
A plant evaluation device and method that acquires and outputs an index value reflecting both operating rate and energy consumption, allowing for the specification of a higher index value when energy consumption is lower and operating rate is higher, or vice versa, based on acquired quantities, including performance and quality data, with optional prediction and alarm features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If OEE is used to evaluate production effectiveness, then production effectiveness is improved, but energy efficiency evaluation is worsened
Solution Approach 1:
The patent combines OEE (production effectiveness indicator) and energy consumption rate (energy efficiency indicator) into a single integrated evaluation system. The acquiring unit simultaneously obtains both indicators, and the determining unit specifies an index value that reflects both production effectiveness and energy efficiency together, resolving the contradiction by merging previously separate evaluation metrics into one comprehensive indicator.
Solution Approach 2:
The patent creates a universal index value that serves multiple evaluation purposes simultaneously. This index value can evaluate both production effectiveness and energy efficiency, making it a multi-functional indicator that replaces the need for separate evaluation systems and enables comprehensive plant assessment with a single metric.
2Loss of energy
If energy consumption rate is used to evaluate energy efficiency, then energy efficiency is improved, but production effectiveness evaluation is worsened
Solution Approach 1:
The patent merges energy consumption rate and OEE into a unified evaluation framework. Instead of using energy consumption rate alone (which would miss production effectiveness information), the system combines both indicators to create an index value that simultaneously reflects energy efficiency and production effectiveness, resolving the limitation of using energy metrics in isolation.
Solution Approach 2:
The resulting index value serves as a universal indicator that can evaluate both energy efficiency and production effectiveness, making the evaluation system multi-functional. This single index replaces the need for separate energy-only evaluation and enables comprehensive assessment of plant performance.
3Loss of energy
If both OEE and energy consumption rate are monitored separately, then production effectiveness and energy efficiency are improved, but evaluation complexity is worsened
Solution Approach 1:
The patent combines multiple separate monitoring functions into a unified evaluation process. The acquiring unit obtains both OEE and energy consumption rate, and the determining unit integrates these into a single index value, reducing evaluation complexity while maintaining comprehensive assessment of both production effectiveness and energy efficiency.
Solution Approach 2:
The index value serves as a universal indicator that consolidates multiple evaluation functions. Instead of requiring separate analysis of OEE and energy consumption rate, this single multi-functional index provides comprehensive plant evaluation, simplifying the overall evaluation process while capturing both productivity and energy efficiency aspects.
Data Source
AI summary
An acquisition unit acquires a quantity relating to an operating rate of a facility of a plant and a quantity relating to energy consumption of the facility. An index value specification unit specifies a higher index value as the energy consumption is lower, and a higher index value as the operating rate is higher, or a lower index value as the energy consumption is lower, and a lower index value as the operating rate is higher, based on the quantity acquired by the acquisition unit. An index value output unit outputs information relating to the index value.