ROADSTONE is the leading manufacturer and supplier of building materials in Ireland. It is strongly committed to energy efficiency and environmental sustainability. Roadstone’s strategy involves developing IS393 certified energy-management systems to drive energy efficiency. It is currently certified to the standard in nine quarries, with an additional ten planned for 2009. The Bunratty, Co Clare quarry was certified in 2008. As a result of Roadstone’s membership of SEI’s Energy Agreements Programme and participation in the Alternative Methodologies Special Working Group, a project was undertaken to improve energy performance at Bunratty using alternative methods.
The initial intent was for SEI to work with Roadstone to investigate an opportunity to perform a Six Sigma project on the Blacktop process, diagnosing the variability in input process and material variables which link to energy usage, and controlling the quality of the end product. Preliminary data analysis suggested a variability in the amount of energy required to process batches and this could vary by up to +/-15%. This indicated that the process was not in ‘statistical control’. Historically, there has been an acknowledged high reject rate of aggregate produced for tar processing at Bunratty’s Blacktop plant. Click here to find out more on Roadstone