ESPIRE is a partnership project between Training and Development Centers of the Bavarian Employers‘ Association (bfz) gGmbH, Small & Medium Enterprises Development Authority (SMEDA) and textile associations in Pakistan. The objective of ESPIRE is to support the industry to work economically more efficient and ecologically sustainable.

ESPIRE has designed a set of tools to help industry measure and improve their energy performance.

The tools calculate the energy efficiency of a company and estimate potential energy and cost savings. The results generated by these tools are estimated based on models and help to determine which equipment or practices are worth pursuing to reduce energy consumption.

The companies can contact ESPIRE team or the experts involved in developing these tools using the contact information provided within the tools.

An on-site energy audit may be beneficial to uncover other energy conservation measures not addressed by these tools.

TOOL FOR PUMPING SYSTEMS

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Conduct a Self-Assessment of your Pumping System to calculate both Energy Per­formance of Pumps and Energy Saving Potentials, using this tool consisting of:

·       Checklist for Pump And Pumping System

·       Pump Efficiency Calculator

·       Pump Energy Performance Calculator

TOOL FOR BOILERS AND STEAM SYSTEMS

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Conduct a Self-Assessment of your Boilers and Steam System, and calcula­te both Energy Performance of your Boilers and Energy Saving Potentials in your System, using this tool consisting of:

·       Checklist for Hot Water & Boiler System

·       Boiler Cost and Efficiency Calculator

·       Calculator for Combustion Efficiency of Boiler

·       Steam Leakage Cost Calculator by using size of Orifice

·       Energy Saving calculation by Insulating hot surfaces

·       Energy Saving calculation by Condensate recovery

·       Energy Saving Calculation by installing Economizer

TOOL FOR MOTORS

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Conduct a Self-Assessment of your Motors and calculate Saving Potentials through Replacement of Motors and/or installing Variable Speed Drives, using this tool consisting of:

·       Checklist for Energy Saving Options in the Motors

·       Energy Saving Calculator (Installing High Efficiency Motor)

·       Energy Saving Calculator (Installing Variable Speed Drive)

TOOL FOR COMPRESSED AIR SYSTEMS

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Conduct a Self-Assessment of your Compressed Air System to calculate both Energy Performance of Compressors and Energy Saving Potentials, using this tool consisting of:

·       Checklist for Energy Saving Options in the Compressed Air System

·       Compressor Energy Cost Calculator

·       Energy Saving through Pressure Reduction

·       Leakage Cost Calculator - Offline Method

·       Leakage Cost Calculator through Orifice Size

·       Energy Saving by Installing High Efficiency Motor

·       Energy Saving by Installing Multiple-stage Compressor

·       Energy Saving by Installing Variable Speed Drive

·       Waste Heat Recovery from Compressor

TOOL FOR CALCULATING COST OF ELECTRICAL ENERGY MIX

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Calculate the total costs of your individual electrical energy mix, based on the different energy sources that your company uses: grid power, diesel generator and gas generator.

ENERGY MANAGEMENT MATURITY MATRIX

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The Energy Management Maturity Matrix is based on Performance Levels defined in accordance with the Energy Management System ISO 50001. The Matrix helps you to assess the level of implementation of the energy management system in the company and identify areas where further development and consideration is required.

CHECKLISTS FOR SELF ASSESSMENT

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This tool unites several Checklists that help you to conduct a Self-Assess­ment of your existing systems and performances in the following fields:

·       Checklist Hot Water & Boiler System

·       Checklist Power generation and distribution

·       Checklist Motors

·       Checklist Pump & Pumping System

·       Checklist Compressors

·       Checklist Lighting System

MAXIMUM DEMAND INDICATOR (MDI) MANAGEMENT TOOL

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Investigate opportunity of reducing the MDI of your company by impro­ving Load Management of utilities and processes at shift start-ups and/ or while connecting to grid power supply.

Who we are:

Training and Development Centers of the Bavarian Employers‘ Association (bfz) gGmbH is one of the largest providers of vocational training in Germany.

The International Division of bfz conducts development cooperation projects on behalf of World Bank, European Union, and the German Government in all parts of the world.

In Pakistan bfz‘s objective is to support the industry to work economically more efficient and ecologically sustainable.

Small & Medium Enterprises Development Authority (SMEDA) is an important Network Partner of bfz. As an autonomous body, it closely interacts with SMEs and provides technical services in the areas of energy management, producti­vity enhancement and quality improvement.

Business associations are partners of bfz and guarantee outreach and sustainability of the activities. These associations include Pakistan Hosiery Manufacturers and Exporters Associations, Pakistan Readymade Garments and Exporters Associations, Towel Manufacturers Association, and Pakistan Association of Automotive Parts and Accessories Manufacturers. These associations are the link to the individual industries, helping with need assessment and promoting project activities. Furthermore the associations plan, organize and conduct events and trainings with network partners to guarantee sustainability of ESPIRE project activities.

The project is supported by the German Ministry for Economic Cooperation and Development (BMZ) and Sequa gGmbH.

Contact:

E-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.

Phone Sindh: +92 (0) 302 82 70 224

Phone Punjab: +92 (0) 305 55 52 343

More information: www.espire.com.pk

 

The role of Seminars and Workshops cannot be overlooked in this age of incessant knowledge creation and deployment of effective change process accordingly. Industry Support Programme of SMEDA has been able to prosper its knowledge assets over the years from various indigenous and foreign sources. Our training Programmes are entitled to disseminate contemporary technique of Productivity Enhancement and Energy Efficiency. We have segregated our stakeholders, with respect to training Programmes, into academia and industry and this collaboration is taking place on mass level. The laxity of industry academia linkages is one of the very crucial reasons for slow development of industry, and industry oriented R&D initiatives on part of academia. SMEDA is playing this vital role by figuring out effective collaboration with academia through imparting necessary awareness among the students and faculty members aspiring the needs of industry. While the objective of collaboration with industry is to engage industry players through associations and chambers to create essential understanding of the basic and advanced concepts related to Productivity and Energy Efficiency required to get competitive edge in today’s volatile global market. We have a simple and effective mechanism to execute the training Programmes. The experts are engaged to demonstrate the contents of each training Programme and participants are provided with the opportunities of cross learning and problem solving ideologies. Different structures of our training Programmes are mentioned here: One day Seminar/Workshop: The Programme is structured to generate awareness among the participants related to a specific topic, as per the request of the potential participants or using other methodologies of need identification. The Programme also is executed at organization level at the premises of potential beneficiary. Two/Three day Training Programmes: The contents of these Programmes are outlined to address multiple issues related to that topic. Such training Programmes also cater the segments like, on the job training, group discussions and case study dissemination. Training of Trainers:  Due to limited availability of developed human strength in the field of Productivity Enhancement and Energy Efficiency, we aim at capacity building of the indigenous resources through conducting ToTs which entail the collaboration of academia and industry at a single forum. The participant carries with them the necessary knowledge to execute at their factory premises and thereof developing their own teams.  No. of Training Workshops / Seminars conducted by SMEDA - ISP Sector No. of Trainings/ Workshops/ Seminars Knitting 1 Spinning 1 Garments 19 Auto Parts 32 Foundry 1 Energy Efficiency 20 Export Leather Marketing 1 Processing 1 Multiple Sector -Textile/Auto 6 Pharmaceutical 1 Fan Sector 2 Total 85

 

Acute energy shortage is the supreme challenge of Pakistan. Most of the industrial sectors in Pakistan are energy intensive and are vulnerable to high rate of energy losses across various production processes resulting in higher energy bills and productivity losses. This problem has significant financial impact on the industrial sectors and severely affects the competitiveness in export markets. The energy cost as a share of total production cost ranges from 20% to 50% in different industrial sectors. Currently, there is a little awareness and even less expertise is available to counter this issue. Keeping in view the strong need for energy savings and skill development and in order to achieve best energy management practices, SMEDA in collaboration with its international partners like German International Cooperation (GIZ) and Training & Development Centers of Bavarian Employers’ Association (bfz- Germany) is providing following services to the industry relevant to its Energy Efficiency Initiatives:  Energy Audits SMEDA is conducting Energy Audits in different industrial sectors (e.g. Textile, Jute, Automotive, Furniture, Marble etc) through Energy Efficiency Experts. Academic institutions are also involved in this Programme as their students get trained on energy efficiency and auditing. The experts develop Energy Programme for beneficiary units proposing remedial actions, their feasibility and implementation plan. Implementation of Energy Management System (EnMS) An energy management system, like all other management systems, is cyclical in nature. It is a formal system, which requires the support at all levels within the company. Once implemented, it offers a structured approach in dealing with energy issues and is the basis for continuous improvement. EN16001 and ISO50001 are the standards for Energy Management System aiming to help organizations in establishing the systems and processes necessary to improve energy efficiency. This leads to reductions in cost and greenhouse gas emissions through systematic management of energy. The stepwise approach for EnMS implementation is; Development of an energy policy Appointing an Energy Manager and Energy Team Conduct of Initial review/ Baseline Audit Development of an Energy Programme Establishing documentation system Setup/strengthen Energy information system Carryout Internal audit/ System evaluation As a result of Energy audits and Energy Management System, depending upon the nature of sector, identified energy saving potentials in some of the industrial sectors are as follows: Sector  Energy Saving Potential Marble  5 to 8% Power Looms  up to 10 % Furniture  15 to 20% Autoparts 10 to 15% Jute 10 to 15% Textile  10 to 30% Energy Manager Training (EMT) Programme  Energy Manager Training is designed for professionals involved in energy management in the industry. EMT aims to develop capabilities of industry professionals in the area of Energy Efficiency and Management to make the industry self reliable in this field. The syllabus for this training has been developed under the guidance of German and Japanese energy experts. This 5 day training Programme consists of Management and Technical issues related to generation and usage of energy. The syllabus contains Introduction to Energy Management System, Energy Information System and Energy Efficiency Potential in Industrial Utilities. The training is offered twice a year. Development of Energy Service Companies (ESCOs) SMEDA is promoting EnMS implementation on performance contracting mechanism in SME based energy intensive sectors having potential of implementing energy saving measures. For this purpose, SMEDA is developing Energy Service Companies (ESCOs) on the subject of Energy Management System (EnMS) detailed practical training and later on, the developed ESCOs will be engaged in EnMS projects on performance contracting basis in different industrial sectors. No. of assisted Units through SMEDA-ISP under Energy Efficiency Initiatives Sector   No. of Assisted Units through SMEDA-ISP Energy Efficiency Initiatives Energy Audits Spinning 10 Weaving 8 Processing 10 Jute 1 Auto Parts 2 Furniture 1 Marble 10 Total 42 Energy Management System Spinning 25 Weaving 4 Processing 4 Total 33 Companies interested to participate in these Programmes may contact by letter, fax or email to the under mentioned. Haseeb Sarwar Manager  Industry Support Cell-Lahore  This email address is being protected from spambots. You need JavaScript enabled to view it. Fouzan Muhammad Deputy General Manager  Industry Support Cell This email address is being protected from spambots. You need JavaScript enabled to view it. Syed Babar Umar Manager Industry Support Cell-Karachi This email address is being protected from spambots. You need JavaScript enabled to view it.

 

Strategically speaking, organizations strive to excel by using cost leadership or differentiation or mix of both strategies. At SMEDA, under Industry Support Programme, we facilitate in either way, by conducting a detailed evaluation phase to investigate current situation of the manufacturing concern and subsequently delineating and implementing a viable solution by adopting a set of Industrial Engineering Tools and Techniques. 

It is imperative to underscore the importance of modern paradigm of Industrial Engineering Tools and Techniques in Pakistan, where Finance intensive initiatives have been considered to be the only endeavors in enhancing the productivity of ongoing businesses. Most of the times, this mind set only brings more chaos to the companies as resource output compared with resource input yield a low value of productivity. 

In contrast, at SMEDA, a team of professional engineers, trained by the Foreign Experts from international organizations (Japan International Cooperation Agency- JICA, Asian Productivity Organization- APO, Senior Experten Service- SES and United Nations Industrial Development Organization -UNIDO) has been unveiling the enormous potentials of Productivity and Quality by optimizing the utilization of the available resources, a proven source of success for one of the leading economy of world, like Japan, and has been transferring this knowledge asset to the grass roots of local industry, especially SMEs. 

The challenge of low productivity and poor quality due to line balance losses, poor housekeeping, piled up inventories, excessive material and operator motions, absenteeism, small quantity orders, high throughput times, high rework rates and inappropriate capacities of top and middle management have been exerting immense pressure on the Manufacturing Concerns which can only be resisted by endeavoring internal strengths. 

SMEDA engineers work at the shop floors of industrial units in association with the technical representatives of the respective companies for practical demonstration and implementation of Productivity and Quality concepts and its Philosophies. Our Productivity initiatives address the aforementioned problems by creating a culture in which everyone in the organization continuously strives to improve the processes and production, minimize delays, reduce costs and improve quality, thus, providing maximum value to the customers and sustainability to the organization. 

Productivity Programmes:
Depending upon the specific requirements of any industrial concern, SMEDA provides productivity and quality improvement expertise on short term as well as on long term basis. 

In the short term activity module; basic training related to different industrial engineering tools and techniques is conducted on beneficiary’s premises and tasks/assignments are given to the participants in order to equip the shop floor personnel to counter the existing problems. Duration of this activity varies from four to six working days in a span of 1-2 months.

To carry out a long term activity module related to productivity and quality, a team of SMEDA engineers along with available productivity expert (foreign or local) works at the selected unit for two to four months. Current situation of the selected unit is evaluated and different industrial engineering tools and techniques, as per the requirements of the manufacturing unit, are deployed in order to achieve the target of enhanced productivity. Follow-up visits are made to ensure the sustainability of the achieved results.

No. of assisted Units through SMEDA-ISP under Productivity Initiatives

 

Sector

	No. of Assisted Units through SMEDA-ISP
Productivity Initiatives
Spinning	42
Weaving	41
Knitting	36
Garments	66
Auto Parts	87
Furniture	5
Food	2
Foot wear	1
Fan	3
Forging	1
Foundry	5
Chemical	2
Total	291

Companies interested to participate in these Programmes may contact by letter, fax or email to the under mentioned.

Haseeb Sarwar Manager  Industry Support Cell-Lahore  This email address is being protected from spambots. You need JavaScript enabled to view it.

Fouzan Muhammad Deputy General Manager  Industry Support Cell This email address is being protected from spambots. You need JavaScript enabled to view it.

Syed Babar Umar Manager Industry Support Cell-Karachi This email address is being protected from spambots. You need JavaScript enabled to view it.