As introduced in the previous five articles, we at Gigaphoton have promoted various activities to reduce the CoO (Cost of Operation) and, thus, enhance the productivity of our laser equipment at customer sites. This article reports on the results of these activities.
(6) Reduction of CoO: Final Report
6-1. Review of CoO Reduction Roadmap
Figure 1 shows the CoO reduction roadmap that was created in 2007.
Figure 1: CoO Reduction Roadmap (Created in 2007)
We at Gigaphoton have reduced the cost of operation (CoO) as set out in this roadmap. However, the actual number of pulses consumed has differed from the number that we forecast then, and this difference has caused the CoO to be changed. Therefore, we re-calculated the CoO to correspond to the actual status.
6-2. Recalculation of CoO
In 2007, we calculated the CoO based on the assumption that the annual number of pulses consumed is 15 billion pulses. According to the pulse consumption database at Gigaphoton, however, we found that the average number of pulses consumed by a GT40A system in 2008 was 24 billion pulses. Since the actual number of pulses consumed was greater than the assumed number, the ratio of the cost of consumables (CoC) in the CoO was increased, as shown in figure 2. Figure 3 shows both the cost of consumables (CoC) by modules and the cost of down time (CoD) by downtime types.
Figure 2: CoO Recalculation Result (Based on reduction achieved in 2008)
Figure 3: Detailed CoO Recalculation Result
6-3. CoO Reduction
6-3-1 CoO Reduction Achieved in 2007
Figure 4 shows the CoO reduction measures taken and the reduction result achieved in 2007. In order to reduce the CoC, we succeeded in prolonging the lives of the chemical filters and laser chambers; this reduced the CoC by 14%.
For the CoD, we succeeded in prolonging the life of the laser gas, thereby reducing the number of gas refills. This resulted in a 13% reduction of the CoD.
As the result of the above measures, we were able to reduce the CoO by 27%.
Figure 4: CoO Reduction Achieved in 2007
6-3-2 CoO Reduction Achieved in 2008
Figure 5 shows the CoO reduction measures taken and the reduction result achieved in 2008.In order to reduce the CoC, we succeeded in prolonging the life of the AMP FM/RM, prolonging the life of the LNM by introducing the MPL, and prolonging the life of the laser chamber by introducing the GRYCOS. The result was a 16% reduction of the CoC.
For CoD reduction, we succeeded in prolonging the life of the laser gas and improving its reliability by introducing the TGM to reduce the number of gas refills. As a result, we achieved a 7% reduction of the CoD.
As the result of the above measures, we were able to reduce the CoO by 23%. That is, we have already achieved a 50% reduction of the CoO compared with the CoO in the beginning of 2007, which is our final goal to be achieved by the second quarter of 2009.
Figure 5: CoO Reduction Achieved in 2008
We could achieve the CoO reduction target of 50% earlier than the scheduled date, thus completing the series of CoO reduction activities that we have promoted since 2007. We believe that we have been able to contribute to achieving high productivity of our laser units at our customer sites though these activities. We at Gigaphoton believe this proves that we have continued to reduce the CoO steadily while keeping our awareness of the CoO high.
However, this is not the end to reducing the CoO. We are now creating a new CoO reduction roadmap, which we will introduce when it has been completed.