Maintenance Management Model for Electrical Energy Conservation in the Production Process of Plastic Film Manufacturing Factories

Abstract

This research aimed to 1) study the elements of maintenance management for electrical energy conservation in the production process of plastic film manufacturing plants. The population consists of individuals responsible for energy conservation, maintenance management, and plastics industry management in three factories from the Eastern Economic Corridor Development Project, with two individuals per factory, totaling six people, 2) create a maintenance management model for electrical energy conservation in the production process of plastic film manufacturing factories. The sample group consisted of 17 experts who evaluated the elements, and the evaluation results were used to design the model, after which a model manual was created. The median and interquartile range were used as statistical measures for data analysis, and 3) certify the maintenance management model for electrical energy conservation in the production process of plastic film manufacturing factories. This process involved testing the model manual with 20 workers in the maintenance department of the plastic film manufacturing industry, evaluating the use of the model, estimating the energy value from using the model, evaluating the completeness of the model, and finally, evaluating the completeness of the manual by six experts.

The research results are as follows:

1. The study of maintenance management components for electrical energy conservation in the plastic film production process, production management process, and overall implementation of energy conservation plans was deemed appropriate in every aspect according to experts’ opinions which was consistent with the research objectives.

2. In creating the maintenance management model for electrical energy conservation, the median values ranged from 3.00-5.00, indicating moderate to very high and highest levels of necessity in the production process of plastic film manufacturing factories, and the interquartile range was 0.00-1.00, showing that the experts agreed. The researcher extracted the elements with the highest consensus among the 17 experts, i.e., the lowest interquartile range (IQR) of 0.00. These elements included maintenance management, Implementation of energy conservation plans, plastic film production process, and production management process. The steps in creating the manual included planning for energy conservation, implementing the energy conservation plan, inspection and monitoring of compliance, and review of energy conservation plans.

3. The certification of the maintenance management model for electrical energy conservation in the production process of plastic film manufacturing factories involved evaluating the use of the models, which had an average rating of 3.80. Implementation was ranked first with an average of 3.95, followed by planning with an average of 3.79, review with an average of 3.74, and inspection and follow-up with an average of 3.72. The comparison of electrical energy values before and after using the model showed reductions in energy consumption across various processes, including the plastic pellet melting process from original 596.00 kW to 575.00 kW, film plastering process from original 578.20 kW to 556.25 kW, film stretching process from original 587.10 kW to 548.15 kW, thin film thickness inspection process from original 510.23 kW to 497.34 kW, and process of cutting rolls according to the size of the film from the original 535.00 kW to 525.60 kW. Considering the average electricity rate in 2023 is 3.64 (baht/kilowatt-hour), the evaluation the completeness of the maintenance management model for electrical energy conservation by six experts found that every evaluation item was 100% appropriate.