Case Study: Heat from Large Ovens Affecting Employees in an Automotive Parts Factory

Problem and Impact

An automotive parts manufacturing plant faced the following issues:

• A large oven (50 meters long) was causing heat radiation in the production area
• Employees in nearby departments were affected by the heat
• Monthly electricity bills were very high due to heat loss from the oven surface

 

Causes

• The large electric oven had a surface area of several hundred square meters
• There was no heat insulation covering the outer surface of the oven
• Heat from inside the oven radiated outwards into the room atmosphere
• The temperature in the work area was higher than 35°C

 

Improvements

1. First method (ineffective):
   • Installed clear curtains to block heat radiation
   • Results were unsatisfactory
2. Effective method:

• • Installed removable insulation on all three sides of the oven surface to reduce heat radiation

 

Results of Improvements

1. Temperature:
   • Oven surface temperature decreased from 75°C to 38.8°C
   • Work area temperature decreased by approximately 1-2°C
2. Energy:
   • Electricity costs decreased by about 22%

 

Lessons Learned

• Managing heat at the source (oven) is more effective than trying to prevent already dispersed heat
• Using removable insulation is an efficient method to reduce heat radiation from high-temperature equipment
• Solving heat-related problems can positively impact the work environment, employee health, and energy savings
• Investing in energy efficiency improvements can help reduce long-term production costs

 

Additional Recommendations

• Consider installing heat insulation on the remaining sides of the oven to further improve energy savings
• Study the feasibility of utilizing the lost heat in other factory processes
• Consider installing localized ventilation systems to reduce the impact of heat on employees in nearby areas
• Develop a regular maintenance plan for the heat insulation to maintain long-term efficiency
• Train employees on safety practices when working with high-temperature equipment and methods to protect themselves from heat.