| 摘要: | 摘要
本研究針對台灣亞熱帶高溫潮濕氣候條件下，製造業常用之氣冷式空壓系統，於夏季高溫期間常發生之壓縮效率下降、能源消耗增加與設備異常等問題，提出一套具系統性之風險分析與節能管理改善架構。以新北市某濾網製造廠為案例，針對空壓主機、儲氣設備、乾燥裝置與關鍵製程進行實地調查與數據盤點，運用FMEA失效模式分析與風險矩陣模型，評估高溫導致各子系統模組（如油氣濾芯、冷卻器、感測器）劣化對產線穩定性與產品品質之潛在衝擊。
研究依循五步驟架構進行，包括：系統邊界確認與資料收集、製程影響分析、風險評估與財損推估、節能改善模擬與方案評選，以及實地導入與成效驗證。模擬階段納入通風強化、排熱導風、濾芯更換頻率優化與感測器補償機制等方案，並依據改善成本、節電量、年效益與碳排減量進行綜合評比。實地導入後之監測結果顯示，系統溫度下降幅度可達5°C以上，不良率明顯降低，能源使用效率與製程穩定性皆有顯著提升，且部分方案回收期僅6個月以內，具良好投資效益。
本研究建構之系統觀導向節能與風險管理方法，不僅可協助中小型廠區改善高溫所致之能源浪費與品質異常，亦提供企業導入制度化空壓管理與持續性監控機制之操作參考，具備高度應用性與推廣潛力，對製造業提升能源效率與韌性營運目標具有實質助益。
;Abstract
This study addresses the common issues encountered by air-cooled compressed air systems in manufacturing environments under Taiwan’s subtropical high-temperature and high-humidity climate, specifically during summer periods. Such conditions often lead to reduced compression efficiency, increased energy consumption, and equipment malfunctions. A systematic framework for risk assessment and energy-saving management is proposed. Using a filter manufacturing plant in New Taipei City as a case study, field investigations and data collection were conducted on key subsystems—including the compressor unit, air receiver, dryer, and critical production processes. Failure Mode and Effects Analysis (FMEA) along with a risk matrix model were employed to evaluate how high-temperature-induced degradation of subsystems (e.g., oil-gas filters, coolers, sensors) can impact production stability and product quality.
The research follows a five-step framework: (1) defining system boundaries and collecting data; (2) analyzing process impacts; (3) performing risk assessment and estimating financial loss; (4) simulating energy-saving improvements and evaluating potential measures; and (5) implementing improvements on-site and verifying outcomes. Simulation scenarios include enhanced ventilation, heat-exhaust ducting, optimized filter replacement intervals, and sensor compensation mechanisms. These scenarios are comprehensively evaluated based on implementation cost, electricity savings, annual benefits, and carbon emission reductions.
Post-implementation monitoring indicates that system temperatures dropped by more than 5 °C, defect rates significantly decreased, and both energy efficiency and production stability experienced noticeable improvements. Some measures achieved payback periods of less than six months, demonstrating strong economic feasibility.
The system-oriented energy-saving and risk management framework developed in this study not only assists small- and medium-sized enterprises in mitigating energy waste and production anomalies due to high temperatures, but also offers a practical reference for institutionalizing compressed-air system management and continuous monitoring mechanisms. This research, therefore, presents substantial benefits for enhancing energy efficiency and operational resilience in the manufacturing sector.
Keywords:
Compressed Air System, Systems Thinking, High Temperature Risk, Energy Management, Heat Source Control |
