Indofood EnCOSS Baseline 1-2 Dec 2016
Indofood EnCOSS Baseline 1-2 Dec 2016
Limbah
Oleh :
Aris Ika Nugrahanto, ST, MBA, CEM, CEAs, (Certified ISO 50001 Lead Auditor)
Suranto, ST (certified ISO 50001 Lead Auditor)
Tujuan Pelatihn
• Peserta memahami pentingnya menyusun baseline dan indikator kinerja yang benar
untuk mengevaluasi kinerja energi, air dan limbah.
• Peserta memahami dan mampu menyusun baseline dan indikator kinerja untuk masing
masing industrinya. Baik untuk level 1 (keseluruhan industry) , maupun level 2 (di
proses atau area tertentu).
• Peserta memahami dan mampu mengevaluasi kinerja energi, limbah dan air untuk
periode Jan-Oktober 2016 dibandingkan baseline di tahun 2015.
• Setiap Divisi di Indofood group memahami cara mengevaluasi keseluruhan kinerja
energi, limbah dan air di divisinya dan mampu mengagregatkan kinerja untuk
keseluruhan indofood group.
Where are we?
MODUL 1 (Sept-Nov 2016)
Form Kesepakatan (1st week Nov 2016) Data Matrix (1st week Nov 2016) Data 2015 dan 2016 (3rd week Nov 2016)
These are the opening words from a fuel efficiency bulletin, published in 1943 by the Ministry of Fuel and Power, which criticises the "ton of coal
per ton of output" metric as a misleading indicator of fuel efficiency.
The author was Oliver Lyle, managing director of the eponymous sugar refinery, a very knowledgeable and eminent engineer who had no time
whatever for the Specific Energy Ratio. Any works engineer today will know that SERs vary continuously for reasons nothing to do with energy
efficiency.
11
Energy per unit of production
140
126
120
100 99
100 95
80
60
40
20
0
2008 2009 2010 2011
Car assembly industry
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Which is right?
-16.74 %
-8.94 %
+2.19 %
Brewing industry
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Typical example
Worse
Better
0.805
0.870
Foundry industry
15
Regression vs SEC
REGRESSION TREND
kWh
baseload
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EXERCISE 1 & 2.
Menyusun Baseline, Indikator Kinerja Energi dan Evaluasi Kinerja
Energi Level 1. Keseluruhan Pabrik
Exercise 1
• Tujuan: baseline untuk konsumsi listrik di Indofood noodle pasuruan
• Baseyear : 2015
• Y : KWh, Listrik Total
• X : Ton, Berat adonan total
• Periode Evaluasi: Jan-Okt 2016
• Susun dan lengkapi, “Baseline Matrix”, sbb:
Bulan Ton Adonan KWh listrik Prediction Diff CUSUM
Exercise II. Develop level 1 Baseline & Performance Evaluation
Metode : Single regression
• Step 1. Buat grafik scatter with only markers untuk X dan Y yang
telah ditentukan di baseline matrix.
• Step 2. add trendline dari grafik tersebut dan munculkan equation
dn nilai R2.
• Step 3. analisa korelasiya ;
a. R2 ≥ 0.75 (IPMVP) berarti well correlated
b. Slope atau koefisien dari X positif.
c. Konstanta atau baseload positif.
Understand and interpret results
• R2:
– What does the R2 mean?: % of variation explained by variables
• High R2:
a) If all predicted variables were included:
a) Strong correlation. Not necessarily good performance.
b) If not all predicted variables were included. Think why.
a) The other ones were not really variables.
b) Saving Opportunities in operational control.
• Low R2:
a) There are other variables.
b) Saving Opportunities in operational control.
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Exercise II. Develop level 1 Baseline & Performance Evaluation
Bulan Liter saos Liter kecap Liter sirup KWh listrik Prediction Diff CUSUM
Exercise III. Develop Baseline & Performance Evaluation with
Multiple Variabel
• Step 3. Klik Data > Data Analysis > Regresi
Pilih data X1 sampai Xn di bagian data X
Pilih data Y dibagian data Y, lalu klik OK, Maka akan keluar
data sebagai berikut di sheet baru di excel.
Exercise III. Develop Baseline & Performance Evaluation with
Multiple Variabel
Step 4. Lakukan analisa terhadap annova yang dihasilkan oleh step 3. meliputi :
1. Apakah coeficient X1, X2…Xn positif
2. Apakah Konstanta (intercept) positif
3. Nilai multiple R2 diatas 0.75
4. Nilai P Value dari X1, X2…Xn < 0.05
5. Nilai Significant F < 0.1
Apabila 5 persyaratan diatas terpenuhi maka persamaan baselinenya adalah :
Y = a1 X1 + a2 X2 + …an Xn + C
Testing significance of relevant variables
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Understand and interpret results
• P-value:
– What does the P-value mean?: Probability of being significant.
• Low P-value:
a) The variable is significant.
• High P-value:
a) The variable is not significant.
b) Some variables are correlated. Colinearity. Check it.
c) The variable is significant but there are other variables.
d) Saving Opportunities in operational control.
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Testing significance of the model
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Understand and interpret results
• Significance F:
– What does this mean?: Probability of being significant.
• Low Significance F:
a) The model is significant.
• High Significance F:
a) The model is not significant.
b) Some variables are non-linear.
– But:
• Low significance F + high P-value
a) Colinearity
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Exercise III. Develop Baseline & Performance Evaluation with
Multiple Variabel
• Step 5,6 & 7. lakukan seperti langkah langkah untuk single
regresi.
Next for ENERGY
1. Lakukan penyusunan baseline untuk Y dan X yang berbeda,
misal untuk batubara Vs Ton steam.
2. Lakukan penyusunan baseline untuk level 2, misal konsumsi
listrik (KWh) untuk cup noodle Vs adonan (Ton) cup noodle.
3. Baseline level 2 hanya memungkinkan apabila terdapat cukup
submeter.
WASTE/ LIMBAH
Baseline untuk limbah
Untuk waste tidak ada baseload, sehingga baseline dengan
intensity cukup dan tidak memerlukan regresi.
Beberapa baseline untuk limbah antara lain :
Level 1 :
• Solid Waste Non Hazardous (All solid waste non Hazardous –
Domestic Waste) / Processed material or <finish good + reject>
• Solid Waste B3 / Processed material or <finish good + reject>
Baseline untuk limbah
Level 2 :
• Domestic solid waste non B3 / HOK
• Solid Valuable Waste non B3 Recycle rate
• Solid Valuable Waste B3/ Processed material or <finish good + reject>;
Recycle rate.
• Solid Industrial Waste B3/ Processed material or <finish good + reject>;
Recycle rate.
• Liquid waste B3 non industrial waste water / Processed material or <finish
good + reject>, Recycle rate.
• Liquid B3 industrial waste water / Processed material or <finish good +
reject>
Exercise IV. Baseline & Performance Evaluation Waste
Exercise IV. Baseline & Performance Evaluation Waste