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Most sites have start-up processes but this rarely includes any consideration of energy efficiency. Everything is simply switched on at the same time and then everybody waits around while the machine warms up. Start-up procedures are needed to bring energy demands on-line at the best/latest possible time.

Shut down of machines should also be carried out properly to reduce energy use. The use of shut-down procedures should be assisted by clearly marked and visible isolation switches that allow complete isolation of the machine services (electricity, compressed air and chilled air) from one simple area with simple on-off valves/switches. Preferably, link downstream equipment to the main machine controls so that when the machine stops then all downstream equipment (conveyors etc.) stops.Action:

• Manage start-ups effectively to reduce unproductive energy consumption.
• Ensure there is a final check of all settings by the setter before the machine is given to Production.
• Set up a ‘shut-down’ area to shut down all unnecessary energy use. Automation will assist here if management is not strong enough. 
• Set up the procedures to minimize energy use when no production is temporarily taking place.
• Document the procedures, and ensure that setters and operators use them. These are not ‘office’ documents but must be used in real life. This is real money.