Improving Compressed Air System Performance
1. Develop a block diagram of your compressed air system
2. Create a system pressure profile
3. Address point of use issues
a. Determine actual air quality requirements and treat air appropriately
b. Investigate and reduce highest point-of-use pressure requirements
c. Investigate and address high-volume, intermittent applications
d. Take stock of what you have and challenge point-of-use requirements and appropriateness (or inappropriateness) or applications
4. Develop a compressed air system maintenance program
(Rotary Screw Maintenance Log Book)
(Piston Maintenance Log Book)
5. Analyze existing compressor(s) and system controls, and implement an effective control strategy
6. Align the supply-side with the demand-side operation
7. Implement strategies to maintain system alignment
8. Communicate to gain support of plant and production management
a. Target the decision-makers
b. Develop a cost-benefit analysis that addresses life cycle cost savings, benefits to production (such as reliability and productivity) and return-on-investment
c. Report to management using and effective format
d. Use pre-measured and post-measurement of kWh and production output to document cost-savings from actions taken with production’s support, and report to management
If your company implements this eight-step action plan as part of a continuous improvement process, your compressed air system will be at its optimal level.