ON-LINE ENERGY-USE BENCHMARKING SYSTEM FOR INDUSTRIES IN MALAYSIA By KAMALA ERNEST Thesis Submitted to the School of Graduate Studies, Universiti Putra Malaysia, in Partial Fulfilment of the Requirements for the Degree of Master of Science February 2004 i
ii
Abstract of thesis presented to the Senate of Universiti Putra Malaysia in fulfillment of the requirement for the degree of Master of Science ON-LINE ENERGY-USE BENCHMARKING FOR INDUSTRIES IN MALAYSIA By KAMALA ERNEST February 2004 Chairman: Syed Abdul Rahman Al-Haddad Faculty: Engineering The study is intended to explore the viability of developing a web-based tool to facilitate a holistic approach to energy-use benchmarking management in the Malaysian Industrial sector. Energy-use benchmarking uses the measure of the plant s specific energy consumption to assess its energy performance, which latter can be used as a baseline for future energy efficiency and energy conservation activities. The measures can also be used to chart out future energy policies related to the development of national energy sector. The system developed is a migration of the manual data collection system which has limitations to the number of companies that can use the same. The energy-use benchmarking community which is customarily known as the Industrial Energy Efficiency Community (IEEC) was created as part of the National Productivity Corporation s (NPC) Benchmarking On-line Networking Database (BOND). Currently, the community has a membership of industries from eight energy intensive sectors in Malaysia, and this will be extended to the entire industrial sectors in stages. iii
Among others, the on-line tool developed can perform automatic statistical analysis in computing energy-use benchmarks, evaluating performance of the community, and ranking companies performance according to selected indicators. In order to evaluate the usability of the system, a sample of four companies from the wood sector were selected. A survey conducted among the selected factories on the usability of the system showed 83 % favorable. However, there are still opportunities available for enhancement of the tool for better usability that can result in more competitive benchmarking analysis. Further descriptive statistics can be derived from the collected and analyzed data. Analysis shows that there is a performance gap of 59 % among the selected sample companies, which can work together to close this gap through end-use energy efficiency. Through daily monitoring and setting targets for determining slack in energy performance and improving end-use energy efficiency respectively, the participating industries can arrest not only fast depletion of fossil fuel reserves but also the negative impact to the environment due to the excessive emission of greenhouse gasses (GHG). iv
Abstrak tesis yang dikemukakan kepada Senat Universiti Putra Malaysia sebagai memenuhi keperluan untuk ijazah Master Sains SISTEM PANGKALAN DATA SECARA ON-LINE UNTUK TANDA ARAS PENGGUNAAN TENAGA DI SEKTOR PENGELUARAN DI MALAYSIA Oleh KAMALA ERNEST Februari 2004 Pengerusi : Syed Abdul Rahman Al-Haddad Fakulti : Kejuruteraan Kajian mencadangkan satu aplikasi pengkomputeran antara manusia dengan komputer dibangunkan untuk memudahkan aktiviti tanda aras penggunaan tenaga di kalangan industri di Malaysia. Tanda aras penggunaan tenaga megukur tahap penggunaan tenaga secara spesifik terhadap produk yang dikeluarkan. Ini merupakan salah satu cara untuk mengetahui tahap penggunaan tenaga bagi sesebuah industri dan informasi ini boleh dijadikan rujukan pada masa depan mengambil kira faktor kecekapan dan penggunaan tenaga. Sistem yang dibangunkan ini merupakan peralihan daripada sistem pengumpulan data dijalankan secara manual dan penggunaannya amat terhad untuk sesetengah industri sahaja. Oleh itu, sebuah komuniti Kecekapan Tenaga Sektor Pengeluaran ditubuhkan, sebagai sebuah badan atau komuniti kepada rangkaian pangkalan data benchmarking secara on-line menerusi Internet di Perbadanan Produktivit Negara. Pada masa kini, komuniti ini terdiri daripada 8 sektor yang terlibat secara langsung di Malaysia dan pada masa depan ianya akan merangkumi ke seluruh sektor pengeluaran yang lain. v
Sistem yang disediakan di Internet ini adalah percuma. Ianya boleh digunakan untuk mengira analisis statistik dengan cepat. Contohnya : pengiraan penggunaan tenaga benchmark, menilai prestasi komuniti atau sektor yang terlibat, dan tahap/pencapaian industri berdasarkan tanda aras. Dalam menilai tahap penggunaan sistem aplikasi yang dibangunkan ini, satu kajian ke atas satu sub-kelompok komuniti yang terdiri daripada 4 buah industri dari sektor perkayuan, telah dijalankan. Daripada hasil kajian, tahap penggunaan ke atas sistem aplikasi yang diperolehi amat menggalakkan iaitu 83%. Daripada kajian yang dijalankan, analisis dan keputusan yang diperolehi juga berdasarkan daripada data yang dikumpul melalui 4 buah industri yang dinyatakan. Kajian menunjukkan terdapat jurang perbezaan yang besar di kalangan rakan kongsi activiti tanda aras peggunaan tenaga iaitu 59%. Ini menunjukkan potensi yang besar bagi penjimatan tenaga. Sebagai satu proses yang berterusan, satu model perancangan berterusan telah diperkenalkan untuk memastikan dan menggalakkan penggunaan tanda aras penggunaan sebagai satu alat/kaedah untuk mempromosikan kecekapan tenaga dalam sektor industri. vi
ACKNOWLEDGEMENTS First and foremost, I would like to express my sincere gratitude and appreciation to the chairman of my supervisory committee, Tn Syed Abdul Rahman, Department of Computer and Communications Engineering UPM for his guidance, assistance and supervision of this thesis study. My appreciation to my industrial supervisor, Mr. R. Ponudurai, Chief Technical Advisor of the Malaysian Industrial Energy Efficiency Improvement Project (MIEEIP) for his guidance, motivation and strong dedication to see that the study attains a highly practical value for future reference. I would like to acknowledge the Malaysia Energy Centre for supporting the research and providing me with a study grant. I would also like to thank the National Productivity Corporation for the excellent collaboration given in enhancing my research work as an online interactive activity for the future. I also wish to convey my heartfelt gratitude to, Mr. Ramvir Sharma, Manager for Energy Efficiency Technology Demonstration Programme of MIEEIP for his constant support and help. To all my lecturers, friends, relatives and associates who have contributed towards my work. vii
And last but by no means least, to my beloved mother, Mdm. Leela Somasundram and sister, Shamala Ernest for their continuous love, support and encouragement Thank you viii
I certify that an Examination Committee met on to conduct the final examination of Kamala Ernest of her Master of Science thesis entitled On-Line Energy-Use Benchmarking for Industrial Sector in Malaysia in accordance with Universiti Pertanian Malaysia (Higher Degree) Act 1980 and Universiti Pertanian Malaysia (Higher Degree) Regulations 1981. The Committee recommends that the candidate be awarded the relevant degree. Members of the Examination Committee are as follows: Prof. Madya Ir. Dr. Norman Mariun Head of Department Faculty of Electrical and Electronic Engineering Universiti Putra Malaysia (Chairman) Syed Abdul Rahman Al-Haddad Lecturer Faculty of Engineering Universiti Putra Malaysia (Member) Ponudurai Rajamanikam Chief Technical Advisor-MIEEIP Malaysia Energy Centre (Member) SHAMSHER MOHAMAD RAMADILI, Ph.D, Professor/Deputy Dean School of Graduate Studies Universiti Putra Malaysia Date: ix
This thesis submitted to the Senate of Universiti Putra Malaysia and has been accepted as fulfilment of the requirement for the degree of Master of Science. The members of the Supervisory Committee are as follows: Syed Abdul Rahman Al-Haddad Lecturer Faculty of Engineering Universiti Putra Malaysia (Member) Ponudurai Rajamanikam Chief Technical Advisor-MIEEIP Malaysia Energy Centre (Member) AINI IDERIS, Ph.D. Professor/Dean School of Graduate Studies Universiti Putra Malaysia Date: x
DECLARATION I hereby declare that the thesis is based on my original work except for quotations and citations which have been duly acknowledged. I also declare that it has not been previously or concurrently submitted for any other degree at UPM or other institution. KAMALA ERNEST Date: xi
TABLE OF CONTENTS Page DEDICATION ABSTRACT ABSTRAK ACKNOWLEDGMENTS APPROVAL DECLARATION LIST OF TABLES LIST OF FIGURES LIST OF ABBREVIATIONS ii iii v vii ix xi xv xvi xviii CHAPTER 1. INTRODUCTION 20 1.1 General 22 1.2 Background 23 1.3 Research Problem 24 1.3.1 Current Setbacks in Malaysia 24 1.3.2 Impact 24 1.4 Objectives 25 1.5 Organization of the thesis 25 1.6 Summary 27 2. LITERATURE REVIEW 29 2.1 Introduction 29 2.2 Energy consumption trend in Malaysia 30 2.3 Overview of Selected Industrial Sectors 31 2.3.1 Wood sector 31 2.3.2 Cement sector 36 2.3.3 Ceramic sector 37 2.4 Benchmarking and Data Collection Activities 38 2.4.1 Energy Efficiency Benchmarking in the Thai-German EE 38 Promotion Programme (ENEP) 38 2.4.2 Department of Statistics-Malaysia 40 2.4.3 Benchmarking at National Productivity Corporation (NPC) 41 2.5 Development of Human Computer Interaction 43 2.6 Principles in Human Computer Interface 43 2.7 Usability Engineering 46 2.8 Interaction models and Methods for HCI design 47 2.8.1 Linguistic model 49 2.8.2 Seeheim Model 50 2.8.3 PAC-Amodeus Model 51 2.8.4 Model-View-Controller (MVC) 52 2.9 Energy Management Information System (EMIS) 53 2.9.1 Requirement of EMIS 54 2.9.2 Components of EMIS 55 xii
2.9.3 Designing EMIS Requirement at Different Management 56 Level and area in a plant 56 2.9.4 Using the system 58 2.9.5 Summary -EMIS and User Interface features 59 2.10 Typical Benchmarking Model 63 2.10.1 Phase I: Planning 63 2.10.2 Phase II: Analysis 64 2.10.3 Phase III: Integration 64 2.10.4 Phase IV: Action 65 2.11 Combining HCI Techniques for Energy-use Benchmarking 66 2.12 The Need for an Interactive On-line e-benchmarking System 67 3. METHODOLOGY 69 3.1 Introduction 69 3.2 E-benchmark Systems and Industrial Energy Efficiency Community 72 3.2.1 Design Specification 73 3.2.2 Outlook 74 3.3 Application of User Interface Architecture 75 3.4 Operations of the system 76 3.4.1 Level of accessibility and type of users 77 3.4.2 Creating the community 78 3.4.3 Creating Organization Admin 79 3.4.4 Creating Indicator Administration 80 3.5 Types of data collected 83 3.5.1 Energy Consumption data 83 3.5.2 Production data 88 3.5.3 Computation of SEC 89 3.6 Role of user 89 3.7 Generating the output 89 3.7.1 Scores 90 3.7.2 Report 91 4. ANALYSIS AND RESULTS 93 4.1 Introduction 93 4.2 Analysis of HCI application in the e-benchmarking system 93 4.2.1 Recognize diversity and complexity of energy-use benchmarking 94 4.2.2 The Interface Process 96 4.3 Evaluating Usability of the system 100 4.3.1 Understandability 100 4.3.2 Learnability 101 4.3.3 Operatabilty 101 4.3.4 Attractiveness 101 4.3.5 Outcome of evaluation 102 4.4 Benchmarking Analysis 103 4.5 Benchmarking Results 104 4.5.1 Wood sector 104 4.5.2 Cement Sector 108 xiii
4.5.3 Ceramic Sector 110 4.6 Relationship between energy consumption and production 112 4.7 Summary of Results 115 5. RECOMMENDATIONS AND CONCLUSION 116 5.1 Introduction 116 5.2 Advantages/ Benefits of the system 117 5.3 Weaknesses of the system 118 5.4 Constraints of the project 118 5.4.1 Quantum of Data for Analysis 118 5.4.2 Issue of Confidentially 118 5.5 Recommendation For A Sustainable Energy-Use Benchmarking For Industries 119 5.5.1 Enhancement of e-benchmark System 119 5.5.2 Monitoring and Targeting System (M & T) 120 5.5.3 Model for Continuous Improvement 122 5.6 Conclusion 123 REFERENCES 125 APPENDICES 127 BIODATA OF THE AUTHOR 140 xiv
LIST OF TABLES Table Page 3.4.1 : Responsibility and level accessibility...77 3.4.2 : User interface Analysis for Organization Administration 79 3.4.3 : User Interface Analysis for Indicator Administration...82 3.5.1 : List of utilities...86 3.5.2 : Conversion factor for electricity and fuel...87 4.3.1 : Matrix for evaluating usability characteristics...102 4.6.1 : Monthly SEC for Wood 2...113 xv
LIST OF FIGURES Figure Page 1.5.1: Organization flow of thesis...27 2.2.1: Trends in energy demand by sectors...30 2.3.1:Particleboard production process...33 2.3.2: Export of Chipboard from Malaysia...36 2.3.3: International benchmarks for tiles and bricks...38 2.8.1 : Component of Human Computer Interface...48 2.8.2 : Linguistic model...49 2.8.3 : Seeheim Model...50 2.8.4 : PAC Amodeus Model...51 2.8.5 : Model-View-Controller Model...52 2.9.1 : Energy Management Strategies...54 2.9.2 : Energy Accounting Centre...57 2.9.3 : Improving Performance Gap...58 2.9.4 : Plant EMIS operation...61 2.9.5 : Implementing EMIS...62 3.1.1 : Process flow and input for the creation of Industrial Energy Efficiency Community...70 3.1.2 : List of e-communities...71 3.2.1 : Interactive e-benchmark database for Benchmarking Communities...72 3.2.2 : Structure of Benchmarking Community for Industrial Energy Efficiency...75 3.4.1 : Workflow structure of Industrial Energy Efficiency Community...76 3.4.2 : Implementation across cluster/sub clusters...78 3.4.3 : Creating organization administration...80 xvi
3.4.4 : Steps in creating Indicator Administration...81 3.4.5 : Creating Indicator Administration...82 3.4.6 : Data Entry Form...83 3.5.1 : Auto calculation to Giga joules...88 4.2.1 : Cluster and Sub clusters of IEE community...95 4.2.2 : System Interface Process...96 4.2.3 : System shortcuts...97 4.2.4 : Successful completion of activity...99 4.5.1 : Competitive Scores for SEC...106 4.5.2 : Results of ranking...107 4.5.3 : Results Overall...107 4.5.4 : Competitive Scores for Cement 4...108 4.5.5 : Competitive Scores for Cement 1...109 4.5.6 : Competitive Scores for Cement 2...109 4.5.7 : Competitive Scores for Cement 3...110 4.5.8 : Competitive Scores for Ceramic 2...110 4.5.9 : Competitive Scores for Ceramic 5...111 4.5.10 : Competitive Scores for Ceramic 6...111 4.5.11 : Competitive Scores for Ceramic 7...112 4.6.1 : Relationship between electricity consumption and production...113 4.6.2 : Relationship between fuel consumption and production...114 5.5.1 : Enhancement of Industrial Energy Efficiency Community...120 5.5.2 : Monitoring and Targeting System...121 5.5.3 : Energy-use Benchmarking Model...122 xvii
LIST OF ABBREVIATIONS BOND DAS DEDP DoS EC EE EPU EMIS ESCO(s) GDP GEF GHG GoM INEDIS MBS MDF MEC MIEEIP MVC M & T NPC PAC Benchmarking On-line Networking Database Data Acquisition System Department of Energy Development Programme Department of Statistics Energy Conservation Energy Efficiency Economic Planning Unit Energy Management Information System Energy Services Companies Gross Domestic Product Global Environmental Facility Green Houses Gasses Government of Malaysia International Network for Energy Demand Analysis for Industrial Sector Malaysian Benchmarking Services Medium Density Fibreboard Malaysia Energy Centre Malaysian Industrial Energy Efficiency Improvement Project Model Viewer Controller Monitoring and Targeting National Productivity Corporation Presentation-Abstraction-Controller xviii
PTM SEC TFP TQM UVM UMIS Pusat Tenaga Malaysia Specific Energy Consumption Total Factor Productivity Total Quality Management User Virtual Machine User Management Information System xix