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Mini Kaizen#87

Reducing Electricity Consumption in Hot Presses with Scheduled Start/Stop

The oil generators used to heat the molds were running continuously, including during periods when the production process was not active.During tea breaks and lunch breaks, the generators could remain...

25 September 2026

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Yener Esen

KAIZEN A3 REPORT

Mini Kaizen - Quick Improvement

Team:

BEFORE

State before kaizen

Oil generators used for mold heating were running continuously.
Generators continued operating during tea and lunch breaks unless manually switched off.
Heating continued even when production was temporarily inactive.
This created unnecessary electricity consumption.
Energy consumption increased during non-working periods.
The process depended on operators remembering to switch the generators off.

A hot-press production area where the oil generator used for mold heating operates continuously. The consumption graph shows energy use continuing even during tea and lunch breaks.
Main message:
The generator keeps running even when production is not active.

Caption: A hot-press production area where the oil generator used for mold heating operates continuously. The consumption graph shows energy use continuing even during tea and lunch breaks. Main message: The generator keeps running even when production is not active.

AFTER

State after kaizen

The generators were connected to digital time relays.
Operating times were programmed according to the production schedule.
Automatic start/stop was enabled.
Generators no longer operate during planned inactive periods.
Manual intervention by operators was reduced.
Unnecessary electricity consumption during breaks was prevented.
The improvement created an energy-saving opportunity through simple automation.

The same energy-consumption graph after the improvement. A digital time relay automatically controls generator operation according to the working schedule, creating clear gaps in energy consumption during planned breaks.
Main message:
Scheduled start/stop prevents energy consumption during inactive periods.

Caption: The same energy-consumption graph after the improvement. A digital time relay automatically controls generator operation according to the working schedule, creating clear gaps in energy consumption during planned breaks. Main message: Scheduled start/stop prevents energy consumption during inactive periods.

Problem Statement / Theme

The oil generators used to heat the molds were running continuously, including during periods when the production process was not active.

During tea breaks and lunch breaks, the generators could remain on unless they were manually switched off. This resulted in unnecessary electricity consumption.

The generators were connected to digital time relays and programmed according to the working schedule. This enabled automatic start/stop during planned non-working periods.

As a result, electricity consumption during breaks and other inactive periods was eliminated, creating an energy-saving opportunity without requiring operators to manually control the generators.

Lean principle:
When equipment operation is aligned with the actual working schedule, energy waste can be eliminated without adding work for the operator.

Reducing Electricity Consumption in Hot Presses with Scheduled Start/Stop

KAIZEN A3 REPORT

BEFORE

AFTER

Problem Statement / Theme

Team Formation

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