Energy Consumption Rate Evaluation Method Considering Occurrence of Defective Products and Misjudgment of Inspection Machine in Production Line

Abstract

In recent years, reducing energy consumption has become a key issue in the industrial world. Therefore, industrial corporations must develop methods of pre-evaluation and production management for reducing their energy consumption while maintaining productivity. Moreover, production lines occasionally generate defective products, reducing the productivity and wasting energy, which affects the energy consumption per unit of production. These production lines require inspection machines to exclude defective products. The layout and configuration of inspection machines change when defective products are excluded, which affects the energy consumption per product. However, no methods have been developed for evaluating the energy consumption per product by considering the number of defective products and the layout and configuration of the inspection machines. In this study, we formulated the energy consumption rate of a production line that generates defective products as the production planning and management method. Specifically, we developed a formula for the energy consumption rate of a production line by considering the defect rate of its production machines and the layout and configuration of the inspection machines. A simulation involving a semiconductor manufacturing line was conducted to validate the proposed theory.