The push for CO2 reduction: Industry meets climate challenges

Recently, I came across an interesting piece of news that underscores the urgency with which companies are addressing the global challenge of reducing carbon dioxide (CO2) emissions. Qemetica Glass (formerly CIECH Vitro) has announced plans to significantly reduce its CO2 emissions. By 2029, the company aims to lower emissions by 20% compared to its 2019 levels, with an investment of around 70 million PLN. Although the news is from September, it remains highly relevant as more and more companies are committing to ambitious environmental targets.

This announcement reflects a broader trend across industries. As climate regulations tighten and consumers demand more sustainable products, companies are under immense pressure to innovate and adopt greener practices. The goal of climate neutrality by 2050 has become a global benchmark, and businesses are recognizing that investments in sustainable technologies are not just a social responsibility, but also a competitive advantage in the market.

Poland leading the way in CO2 reduction

Interestingly, Poland has been making notable progress in reducing its emissions. Last year, Poland's CO2 reduction efforts accounted for a quarter of the total CO2 reduction in the European Union, which is a significant achievement. This has placed Poland ahead of many other EU countries in terms of emission reduction per capita, trailing only Germany and the Netherlands. This demonstrates that Polish industry is actively stepping up to meet the challenges of reducing carbon emissions, despite being a country heavily reliant on coal.

However, while Poland is making impressive strides in reducing emissions overall, there is still considerable room for improvement when it comes to optimizing industrial efficiency, particularly in the area of OEE (Overall Equipment Effectiveness). Conversations I’ve had with industry experts suggest that OEE is often below the expected standards, and this is an area that could have a direct impact on emissions.

The role of OEE in industrial performance

For those unfamiliar, OEE is a widely-used metric for measuring the productivity of manufacturing equipment. It takes into account three key components: availability, performance, and quality. Essentially, OEE measures how well a piece of equipment is being used compared to its full potential. A high OEE score indicates that the equipment is running as efficiently as possible, producing high-quality output with minimal downtime.

Improving OEE can lead to better operational efficiency, reduced costs, and higher output. However, despite its importance, OEE is often overlooked or not given the attention it deserves in many industries. This is surprising, especially considering that optimizing OEE can have a direct impact not only on profitability but also on sustainability efforts, including reducing CO2 emissions.

Little digression: OEE and CO2 emissions

When considering the relationship between OEE and CO2 emissions, it might seem intuitive that improving equipment effectiveness would lead to a reduction in emissions. After all, if equipment is running more efficiently, it should be using less energy, producing less waste, and therefore emitting fewer greenhouse gases. This is often true, but the relationship between OEE and CO2 emissions is not always so straightforward.

OEE is a purely operational metric—it measures the efficiency and effectiveness of equipment without taking into account its environmental impact. While a high OEE score generally indicates that equipment is running efficiently, it doesn’t necessarily mean that it’s running in an environmentally friendly way. For instance, a machine might be operating at full capacity, but if it’s using outdated or energy-inefficient technology, it could still be producing significant amounts of CO2.

OEEE: A more comprehensive measure

This is where OEEE (Overall Environmental Equipment Effectiveness) comes into play. OEEE is an extension of OEE that incorporates environmental factors into the equation. While OEE measures how well equipment is being utilized, OEEE adds a layer of analysis by considering the environmental impact of the equipment's operation—specifically its energy use and the emissions it generates.

By including environmental impact in the calculation, OEEE provides a more comprehensive view of equipment performance. It allows companies to not only optimize their operations but also make informed decisions about sustainability. In this context, OEEE becomes a far more precise measure when it comes to understanding how equipment contributes to both productivity and emissions reduction.

However, despite the clear advantages of OEEE, many companies continue to rely on OEE as their primary metric. This is largely because OEE is easier to calculate and optimize. OEEE requires more complex data collection and analysis, which can be a barrier for companies that don’t have the necessary infrastructure or expertise in place.

The connection between OEE, OEEE, and CO2 emissions

In practice, optimizing OEE can still lead to lower CO2 emissions, but it’s not guaranteed. A company might improve its OEE by increasing production speed or reducing downtime, but if these improvements lead to higher energy consumption, the overall environmental benefit might be negated. This is why it’s important to consider OEEE alongside OEE—by focusing on both operational efficiency and environmental impact, companies can achieve a more balanced approach to sustainability.

For example, a plant might increase its OEE by improving the availability of its equipment—minimizing downtime and running machines for longer periods. However, if those machines are operating inefficiently in terms of energy use, this could result in higher emissions despite the operational improvements. On the other hand, by using OEEE, the plant could identify opportunities to both improve efficiency and reduce emissions, ensuring that the gains in productivity don’t come at the expense of the environment.

Real-world applications: Improving OEE and reducing emissions

The good news is that OEE can be significantly improved through modern technology. Proper sensor deployment and real-time data analysis software allow companies to monitor equipment performance in detail, identify inefficiencies, and make adjustments in real time. By implementing these tools, companies can optimize their OEE and simultaneously work towards reducing their CO2 emissions.

For instance, sensors can be installed on machines to collect data on various performance indicators, such as energy consumption, production speed, and downtime. This data can then be analyzed in real time to identify patterns and areas where improvements can be made. By making small adjustments—such as optimizing machine settings, scheduling preventive maintenance, or reducing idle time—companies can boost their OEE and lower their energy use, leading to fewer emissions.

OEE and sustainability goals: What lies ahead

As the pressure to reduce emissions intensifies, more companies are recognizing the need to integrate sustainability into their core business strategies. OEE and OEEE will play crucial roles in this transition, offering a way for companies to measure and improve both their operational efficiency and their environmental impact. However, achieving these goals will require more than just adopting new metrics—it will involve a fundamental shift in how companies approach their operations and measure success.

One of the challenges ahead will be convincing more businesses to adopt OEEE as a standard measure of performance. While many are already using OEE, the additional layer of complexity introduced by OEEE may require a cultural shift within organizations. Companies will need to invest in new technologies, train employees to use these tools, and create a mindset that prioritizes both efficiency and sustainability.

The way forward: Collaboration and innovation

At this point, I’m curious if anyone in my network is working on the topic of OEE, OEEE, or CO2 reduction through equipment optimization. Are you leveraging advanced monitoring and analytics to improve OEE while also focusing on sustainability? I’d love to hear about your experiences and insights on how we can drive progress in this area.

With the right tools and collaboration, industries can meet their climate goals while optimizing performance. There is much to learn from those already leading the way in this space, and together, we can continue to innovate towards a more sustainable future.

Conclusion

The intersection of operational efficiency and sustainability is becoming increasingly important as companies face growing pressure to reduce their environmental impact. By focusing on metrics like OEE and OEEE, businesses can not only improve their productivity but also make meaningful progress toward reducing their CO2 emissions. As more companies adopt advanced technologies like real-time data analysis and sensor deployment, the potential to drive both economic and environmental gains becomes clear.

I’m eager to hear from others working in this space. Let’s share ideas, challenges, and solutions to improve both our efficiency and our sustainability efforts.

Sources:

https://www.kierunekchemia.pl/artykul,106353,qemetica-glass-zainwestuje-70-mln-zl-w-inwestycje-ktora-obnizy-emisje-gazow-cieplarnianych.html https://businessinsider.com.pl/gospodarka/drastyczny-spadek-emisji-co2-w-polsce-unia-moze-sie-od-nas-uczyc/zb951wk https://www.wwf.pl/nowy-cel-ograniczenia-emisji-co2-dla-ue-do-2040-o-90 https://www.mdpi.com/2071-1050/7/7/9031 https://www.sciencedirect.com/science/article/pii/S2351978919310807