Operations
Operations is where the technical improvements are put into practice - it is where the ‘rubber meets the road’. Operations depends on people, improvements are cheap but can often be difficult to implement and sustain. Training and motivation are the key issues in operations. Controlling machine operations (start-up, stand-by and shut-down) is a key factor in reducing energy costs.

Process setting
Optimized settings for production consistency and cycle time reduction will also give optimised energy use. The initial process setting needs a scientific approach to find the best setting and give the best results. These setting must be adequately recorded and used to be effective. No settings should be changed without justification and high-level approval.

Start-up
Start-up should follow setting sheets at all times. Correct sequencing of operations and a simple time-line approach to start-up will reduce energy use dramatically, e.g. in injection moulding there is no logic in turning on the main motor (the major energy use) until the latest possible time. Fast tool changes will reduce energy costs in idling machines.

Stand-by
Machines should be set into ‘stand-by’ when they are not going to be used for a short time, e.g. main motor off, downstream, equipment off. If machines are not going to be operated for more than 4 hours then they should be shut-down. Automation can help here.

Shut-down
Shut-down should take the high energy loads off-line as soon as possible, e.g. in injection moulding then the main motor should be turned off as soon as possible. Automation can help here.

Training
Staff training is one of the quickest and most profitable actions in energy efficiency and can reduce energy use by up to 20%. Training should explain the process, motivate staff and be relevant to the role of the staff. Empowering staff to switch machines/processes/services off can lead to remarkable results.

Maintenance
Maintenance is a key issue in achieving and sustaining the energy efficiency of processes and machines. The maintenance function has a key role to play in both achieving and maintaining energy management.

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