Leak survey identifies big savings for Toyota
An
Eriks UK product story
Edited by the Engineeringtalk editorial team
Apr 22, 2004
Ultrasonic detective work by Wyko at Toyota Manufacturing UK's Derbyshire plant has sounded out considerable energy and cost savings by eliminating air leaks.
Ultrasonic detective work by Wyko at Toyota Manufacturing UK's Derbyshire plant has sounded out considerable energy and cost savings by eliminating air leaks.
As part of a company-wide energy reduction initiative, led by Toyota Manufacturing UK's Energy Committee, Wyko's ultrasonic detection equipment was used in the weld shop to locate air leaks on process equipment and machinery and grade them by their severity.
The facilities department at the car manufacturer is responsible for the supply of water, electricity and compressed air around the plant, its also has a representatives on the company's site-wide energy committee.
An energy usage figure is published weekly by the company in order to monitor efficiency and evaluate any changes made.
Compressed air leakage was identified by the facilities team as a target for energy reduction and cost savings in their capacity as both service provider and on-site energy reduction campaigners.
An investigation of the shop was carried by the facilities starting with the mapping of all air lines.
Wyko then provided a team equipped with the latest acoustic leak detection equipment to carry out a search using the air map guides.
Over a series of weekends all air-powered equipment was tested for air leaks and the results recorded.
Once the air leakage data was logged, the team implemented a series of actions to improve and maintain the compressed air systems.
These included, upgrading of components, implementation of a service contract to identify and repair any new leaks and new standards set for future compressed air installations.
The cost to replace the components responsible for the leaks was remarkably low in comparison to the considerable saving opportunity for the company.
The components consisted of mainly basic items such as filters, regulators and some new pipe work connections.
Although members of the energy committee expected to see significant savings, even they were surprised by the final figure and have used the example to generate interest in energy saving schemes in other departments where they hope similar savings can be made.
These include other shops and on equipment using steam, gas, electricity and water.
Air leak surveys are one of a range of energy saving services available from Wyko that include full energy audits through to specific tasks such as air leaks and electric motor surveys.
Services are available from every Wyko branch nationwide, currently including over 170 sites ensuring there is a local Wyko service provider wherever business is based.
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