Eliminating compressed air leaks in production process on compressor machine using TRIZ decision making – A case study in Somaliland company
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Jun 29, 2025
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Abstract
In Somaliland, electricity is an expensive necessity. The high expense of electricity presents challenges for industrial development in Somaliland. Existing industries must operate efficiently to survive, specifically in the manufacturing sector, which relies heavily on electrical machinery. The compressor is widely used in manufacturing to provide the air supply to production machines, including CNC machines. However, in some cases, the air supply from the compressor is not supplied efficiently due to air leakage in standby mode. This research aims to solve this issue by implementing an integrated system that reduces energy waste caused by compressed air leakage during standby mode. This research is grounded in the application of the TRIZ contradiction matrix, which identified Inventive Principle #28 (Mechanics Substitution) as a potential solution. The proposed solution was subsequently implemented and evaluated using a pilot experimental method within the context of a case study conducted at a manufacturing company located in Hargeisa, Somaliland. The result led to the successful implementation and testing of a control system that integrated the operations of the compressor machine and CNC machine. Compared to the conventional ball valve components, the new system replaced it with an automatic air control valve integrated with the CNC machine emergency button. Electricity consumption on the compressor machine was observed and calculated for twelve months before improvement and twelve months after implementing the improvements. The data was collected for a total of 24 months to compare before improvements and after improvements for each 12 months in a machine. The improvements showed a significant reduction in electricity consumption, from 10,982 kWh to 9,830 kWh representing 10.49% energy savings, and reduced electricity operating costs by SOS 605,952 (USD 1,067) in 12 months.
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References
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[8] M. Jiménez, E. Kurmyshev, and C. E. Castañeda, “Experimental Study of Double-Acting Pneumatic Cylinder,” Experimental Techniques, vol. 44, no. 3, pp. 355–367, Jun. 2020, doi: 10.1007/s40799-020-00359-8.
[9] R. Dindorf, J. Takosoglu, and P. Wos, “Review of Compressed Air Receiver Tanks for Improved Energy Efficiency of Various Pneumatic Systems,” Energies, vol. 16, no. 10, p. 4153, May 2023, doi: 10.3390/en16104153.
[10] C. Panda and T. R. Singh, “ML-based vehicle downtime reduction: A case of air compressor failure detection,” Engineering Applications of Artificial Intelligence, vol. 122, p. 106031, Jun. 2023, doi: 10.1016/j.engappai.2023.106031.
[11] D. Zakiah, A. Hidayat, and B. S. Abdurohman, “Optimization of the Air Compressor to Get Good Compressed Air In MV. Dewi Amabarwati,” Dinasti International Journal of Education Management And Social Science, vol. 4, no. 1, pp. 96–103, 2022, doi: 10.31933/dijemss.v4i1.
[12] Z. Yuan, Q. Zheng, Y. Jiang, B. Jiang, and M. Luo, “Review on power conversion unit of noble gas closed Brayton cycle for space and underwater applications,” Applied Thermal Engineering, vol. 223, p. 119981, Mar. 2023, doi: 10.1016/j.applthermaleng.2023.119981.
[13] G. Zhang et al., “Effect of relative humidity on the nozzle performance in non-equilibrium condensing flows for improving the compressed air energy storage technology,” Energy, vol. 280, p. 128240, Oct. 2023, doi: 10.1016/j.energy.2023.128240.
[14] D. R. Patrick and S. W. Fardo, “Pressure Systems,” in Industrial Process Control Systems, Second., 2021, ch. Chapter 3, pp. 71–130.
[15] R. Dindorf, “Measurement of Pneumatic Valve Flow Parameters on the Test Bench with Interchangeable Venturi Tubes and Their Practical Use,” Sensors, vol. 23, no. 13, p. 6042, Jun. 2023, doi: 10.3390/s23136042.
[16] M. Soori, F. K. Ghaleh Jough, R. Dastres, and B. Arezoo, “Sustainable CNC machining operations, a review,” Sustainable Operations and Computers, vol. 5, pp. 73–87, 2024, doi: 10.1016/j.susoc.2024.01.001.
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[19] Y. Guo, Y. Sun, and K. Wu, “Research and development of monitoring system and data monitoring system and data acquisition of CNC machine tool in intelligent manufacturing,” International Journal of Advanced Robotic Systems, vol. 17, no. 2, p. 172988141989801, Mar. 2020, doi: 10.1177/1729881419898017.
[20] C. Brecher and M. Weck, “Multi-Machine Systems,” in Machine Tools Production Systems 1, 2024, pp. 325–360. doi: 10.1007/978-3-662-68120-6_9.
[21] C. Brecher and M. Weck, “Equipment Components for Machine Tools,” in Machine Tools Production Systems 1, 2024, pp. 361–466. doi: 10.1007/978-3-662-68120-6_10.
[22] L. Zhou, F. Li, Y. Wang, L. Wang, and G. Wang, “A new empirical standby power and auxiliary power model of CNC machine tools,” The International Journal of Advanced Manufacturing Technology, vol. 120, no. 5–6, pp. 3995–4010, May 2022, doi: 10.1007/s00170-021-08274-x.
[23] D. Kaya, F. Çanka Kılıç, and H. H. Öztürk, “Energy Efficiency in Compressed Air Systems,” in Energy Management and Energy Efficiency in Industry, 2021, pp. 395–418. doi: 10.1007/978-3-030-25995-2_13.
[24] Y. Dwianda, “Failure Mode and Effect Analysis (FMEA) of Pneumatic System of CNC Milling Machine,” The Journal of Ocean, Mechanical and Aerospace -science and engineering- (JOMAse), vol. 65, no. 1, pp. 14–18, Mar. 2021, doi: 10.36842/jomase.v65i1.239.
[25] S. Y. Lee, K. H. Han, and D. Shin, “Design of recirculation system and re-valve for increasing the compressing efficiency,” in 2017 14th International Conference on Ubiquitous Robots and Ambient Intelligence (URAI), IEEE, Jun. 2017, pp. 366–367. doi: 10.1109/URAI.2017.7992752.
[26] P. Abers, L. Pickett, J. Sandia, and N. Laboratories, “Simulation of Engine Expansion for Transparent Nozzle Combustion Research,” 2017.
[27] G. Chen, Y. Huang, W. Cai, and F. Ye, “Research on working principle and realization mode of electronic controlled air dryer,” in 2021 4th World Conference on Mechanical Engineering and Intelligent Manufacturing (WCMEIM), IEEE, Nov. 2021, pp. 547–550. doi: 10.1109/WCMEIM54377.2021.00118.
[28] D. Shaw, J.-J. Yu, and C. Chieh, “Design of a Hydraulic Motor System Driven by Compressed Air,” Energies, vol. 6, no. 7, pp. 3149–3166, Jun. 2013, doi: 10.3390/en6073149.
[29] R. J. Setiawan, M. S. Fitrihartanta, M. Mujiono, and D. Nurhadiyanto, “Rancang bangun converter kit sebagai alat konversi energi sepeda motor 100cc berbahan bakar gas LPG,” Injection: Indonesian Journal of Vocational Mechanical Engineering, vol. 1, no. 2, pp. 75–82, 2024, doi: 10.58466/injection.v1i2.1410.
[30] D. Vittorini and R. Cipollone, “Energy saving potential in existing industrial compressors,” Energy, vol. 102, pp. 502–515, May 2016, doi: 10.1016/j.energy.2016.02.115.
[31] H. Q. Shanghai and A. McKane, “Improving energy efficiency of compressed air system based on system audit. Lawrence Berkeley National Laboratory,” 2008.
[32] R. Saidur, N. A. Rahim, and M. Hasanuzzaman, “A review on compressed-air energy use and energy savings,” Renewable and Sustainable Energy Reviews, vol. 14, no. 4, pp. 1135–1153, May 2010, doi: 10.1016/j.rser.2009.11.013.
[33] J. Zahlan and S. Asfour, “A multi-objective approach for determining optimal air compressor location in a manufacturing facility,” Journal of Manufacturing Systems, vol. 35, pp. 176–190, Apr. 2015, doi: 10.1016/j.jmsy.2015.01.003.
[34] L. Ramezani, B. Karney, and A. Malekpour, “The Challenge of Air Valves: A Selective Critical Literature Review,” Journal of Water Resources Planning and Management, vol. 141, no. 10, Oct. 2015, doi: 10.1061/(ASCE)WR.1943-5452.0000530.
[35] X. Li, T. Yan, X. Bi, and L. Fei, “Influence of Traditional and Antislam Air Valve Characteristics on Transient Pressure Control,” Journal of Pipeline Systems Engineering and Practice, vol. 13, no. 3, Aug. 2022, doi: 10.1061/(ASCE)PS.1949-1204.0000660.
[36] R. Dindorf, “Estimating Potential Energy Savings in Compressed Air Systems,” Procedia Engineering, vol. 39, pp. 204–211, 2012, doi: 10.1016/j.proeng.2012.07.026.
[37] C. Galitsky, “Energy efficiency improvement and cost saving opportunities for the vehicle assembly industry: an energy star guide for energy and plant managers,” 2008.
[38] M.-R. Tahan, “Recent advances in hydrogen compressors for use in large-scale renewable energy integration,” International Journal of Hydrogen Energy, vol. 47, no. 83, pp. 35275–35292, Oct. 2022, doi: 10.1016/j.ijhydene.2022.08.128.
[39] M. Chahartaghi, S. E. Alavi, and A. Sarreshtehdari, “Investigation of energy consumption reduction in multistage compression process and its solutions,” Journal of Computational Applied Mechanics, vol. 50, no. 2, pp. 219–227, 2019, doi: 10.22059/jcamech.2018.247328.217.
[40] J. Jantschgi and J. Fresner, “The Usage of TRIZ to improve material efficiency and energy efficiency of industrial production processes - Ideas for a conceptual framework,” in TRIZ Future 2006 (Cleaner Production & TRIZ), 2006.
[41] A. Razaque et al., “Energy-Efficient TRIZ-Inspired Paradigm to Automate Consumer Electronic Devices,” Jan. 29, 2024. doi: 10.20944/preprints202401.1970.v1.
[42] G. S. Altshuller, Creativity as an exact science. crc Press, 1984.
[43] A. Khodadadi and P. von Buelow, “Design exploration by using a genetic algorithm and the Theory of Inventive Problem Solving (TRIZ),” Automation in Construction, vol. 141, p. 104354, Sep. 2022, doi: 10.1016/j.autcon.2022.104354.
[44] V. Sojka and P. Lepsik, “Tools of Theory of Inventive Problem Solving Used for Process Improvement—A Systematic Literature Review,” Processes, vol. 13, no. 1, p. 226, Jan. 2025, doi: 10.3390/pr13010226.
[45] R. P. Guinter, “Emergency stop devices and the human factors of response,” New Jersey Institute of Technology, 1986.
[46] B. P. Madhu, G. Mahendramani, and K. Bhaskar, “Numerical analysis on flow properties in convergent – Divergent nozzle for different divergence angle,” Materials Today: Proceedings, vol. 45, pp. 207–215, 2021, doi: 10.1016/j.matpr.2020.10.419.
[47] S. D. Savransky and C. Stephan, “TRIZ: Methodology of inventive problem solving,” The Industrial Physicist, vol. 2, no. 4, pp. 22–25, 1996.
[48] J. Terninko, A. Zusman, and B. Zlotin, Systematic innovation: an introduction to TRIZ (theory of inventive problem solving). CRC press, 1998.
[49] A. A. Guin, A. V Kudryavtsev, V. Y. Boubentsov, and A. Seredinsky, “Theory of Inventive Problem Solving,” First Fruits, 2009.
[50] G. S. Alʹtshuller, The innovation algorithm: TRIZ, systematic innovation and technical creativity. Technical innovation center, Inc., 1999.
[51] Y.-T. Chen and R. J. Setiawan, “Energy Saving Solution for Welding Process: A SME Case Study of Fume Extractor,” in 2023 IEEE 6th International Conference on Knowledge Innovation and Invention (ICKII), IEEE, Aug. 2023, pp. 720–725. doi: 10.1109/ICKII58656.2023.10332684.
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