Initiatives

Product Initiatives (Energy-savings)

FANUC is promoting energy saving in its products. There are two important initiatives, one is to conserve energy at our customers’ factories using our products. The other is also to conserve the energy in our own factories. Considering the life cycle of FANUC products, the first initiative has a far greater effect on energy-savings. Therefore, we have long been working on developing energy-efficient products.

Development of large-capacity servo motors	We have developed a high-precision, high-efﬁciency, large-capacity servo motor fully utilizing our advanced digital control system. In the ﬁeld of industrial machines, including electric injection molding machines, which require tremendous power, we have realized energy saving by introducing this large-capacity servo motor in place of hydraulic pressure.
Adoption of power supply regeneration system	In the servo ampliﬁer, we use a power supply regeneration system that returns energy to the power supply when the motor decelerates. This effective use of the power supply leads to energy savings. When mounted on a ROBODRILL, it achieves a reduction in energy consumption by approximately 35% compared with the resistance-regeneration method. Furthermore, the adoption of new power devices has continuously reduced energy loss of the servo amplifier. It is reduced by maximum 35% compared to that in 1995.
Provision of the latest servo system	The newly developed αi-D series SERVO system has reduced loss of the entire servo system by 10% compared to the conventional products by reducing copper loss and iron loss of motors and AC reactors by adopting the above amplifier.
Power consumption monitoring function	Through the power-consumption-monitoring function, we have made it possible to monitor the amount of power consumed by our CNC systems, enabling the efﬁcient adjustment of the cycle time. In addition, CO₂ emissions can also be displayed. By using the energy-saving level-selection function, we have made it possible to choose the type of operation: one that prioritizes cycle time and one that prioritizes power consumption. When there are differences in cycle times in the production line, in case fast processing is not necessary, choosing the power consumption priority operation contributes to energy savings for the entire factory. In addition, robots can also display power consumption in real time on the teaching operation panel using a power consumption monitor.
Fast Cycle-time Technology	This series of functions reduces cycle time. Reducing operating time contributes to reductions of energy consumption by peripheral equipment, such as a coolant pump.
Averaging the load of power demand	Night operation using robots disperses peak power and curbs power consumption.
Reducing CO₂ emissions by reducing weight	The design of the robot mechanical arms with lighter weight also reduces power consumption. For the robots with a payload of 165 kg, the Robot S-430iW in 1997 weighed 1,300 kg while the Robot R-2000iC/165F in 2013 is lighter with weight of 1,190 kg. In addition, the collaborative robot CRX has a robot mass of 40 kg with a payload of 10 kg, which is considerably lighter than the robot mass of 150 kg common to robots in the same class thus far, and reduces power consumption. Even the LR-10iA/10 fully enclosed handling robots are more than 1/3 lighter than conventional robots with the same 10 kg payload, and consume 30% to 40% less power.
Optimal operating program	By optimizing the operating program with ROBOGUIDE, power consumption is reduced and the lifetime of the reducer is extended to reduce running costs.
Efﬁcient robot utilization	Use of an autonomously moving, Automatic Guided Vehicle (AGV) with collaborative robots allows a single robot to work in multiple locations, improving the efﬁciency of robots. This reduces standby power, compared with installing multiple robots. In addition, the latest model of the collaborative robot CRX has a very light robot mass of 40 kg, and the AGV can also be made compact. Furthermore, the CRX can be moved on a handcart instead of on an AGV, making it possible to move the robot to the place where and when it is needed.
Instruction operation panel backlight automatically turns off	Reduces power consumption by automatically turning off the backlight of the LCD screen on the robot's teaching operation panel when no operation is performed for a certain period of time.
Energy-saving design	We have developed a new type of heavy payload robot, M-1000iA, with a serial link mechanism that is compact and has a wide motion range. Using the latest structural analysis, the M-1000iA has the necessary strength and rigidity while making extensive use of curved surfaces, at the same time, saving energy through the use of arms designed to be lightweight and power regeneration that reuses the robot's deceleration energy. In addition, we have developed the R-50iA, a new robot controller with an eco-friendly, energy-saving design, which reduces power consumption through the use of low-power fans, amplifiers with low-loss power elements, and highly efficient brake control.
Highly reliable automatic wire feeding system (AWF3)	ROBOCUT is capable of unmanned operation for long periods, thanks to the highly reliable automatic wire feeding system AWF3, which can automatically recover feeding even when a wire is accidentally cut and disconnected. Stable night-time machine operation disperses peak power usage and curbs power consumption.
Discharge control iPulse3	With ROBOCUTs, our newly developed discharge control iPulse3 has reduced the processing time and achieved a reduction in power consumption. In addition, power consumption is reduced by inverter control of the pump and cooler, power regeneration of the discharge circuit, and reduction of standby power for various devices.
Electriﬁcation of peripheral equipment	With the additional axis option for ROBOSHOT, peripheral equipment that was previously driven by hydraulic equipment can be electrified, saving energy.
Heat insulation cover	Covering heaters of injection cylinders of ROBOSHOTs with heat insulation cover increases heat insulation effect and reduces power consumption.
Plasticization energy monitor	By visualizing the breakdown of the energy consumed in the plasticization process (melting of the resin) and the energy loss due to heat dissipation, it supports the adjustment of optimal molding conditions that reduce energy consumption.
Energy-saving functions	The ROBODRILL's sleep function reduces power consumption by turning off the servo motor, stopping the coolant and lubrication pumps while the machine is idle. Furthermore, the peripheral device and mist collector control functions make it easy to extend the same control to other devices, saving energy for the entire system.

Awards/Topics on Energy Saving

ROBODRILLs and ROBOSHOTs became eligible for a subsidy for business expenses supporting promotion of advanced energy-saving investments, allocated in FY2021 supplementary budgets in recognition of their energy-saving potential. (2021)

ROBODRILL α-DiB Plus Series
ROBODRILL α-DiB_ADV Plus Series
ROBOSHOT α-SiA, B Series

ROBODRILLs and ROBOSHOTs became eligible for a subsidy for business expenses supporting businesses rationalizing energy use in production equipment, allocated in FY2019 supplementary budgets in recognition of their energy saving potential. (2020)

ROBODRILL α-DiB Series
ROBODRILL α-DiB_ADV Series
ROBOSHOT α-SiA Series

Approved for subsidies for the introduction of energy-saving equipment for local factories and small- and medium-sized enterprises (2014)

ROBOCUT α-CiA Series

Prize of the Director General of Agency of the Natural Resources and Energy, Excellent Energy Saving Device Award Program by the Japan Machinery Federation (2003)

For our large-capacity servo system with a power regeneration feature and precision digital control and for our large-size AC Servo Motor αi Series

The Minister Award of the Ministry of International Trade and Industry, Excellent Energy Saving Device Award Program by the Japan Machinery Federation (1999)

Digital servo system using phase control regeneration and cycle time reduction, AC Servo Motor α Series

The Minister Award of the Ministry of International Trade and Industry, Excellent Energy Saving Device Award Program by the Japan Machinery Federation (1998)

For our wire-cut electric discharge machines equipped with a high-speed automatic wire feeding mechanism and thick plate tracking control
ROBOCUT α Series

The Minister Awards of the Ministry of International Trade and Industry, Excellent Energy Saving Device Award Program by the Japan Machinery Federation (1995)

ROBOSHOT Series

Production Initiatives

FANUC will contribute to energy-savings in our manufacturing facilities.

Streamlining the assembly process	At the Hayato Factory (Kagoshima Prefecture), cleaning was previously carried out using an ultrasonic cleaning device during the assembly process of ﬂexible cables. However, this process was eliminated by reconsidering the necessity of cleaning in order to reduce annual power consumption (by 158,976 kWh). With Wire Electrical-Discharge Machine (small and medium size), we have achieved great results in reducing assembly man-hours by sharing parts and making significant design changes such as harness unitization through repeated prototyping and design reviews.
Introduction of cogeneration system	We have introduced cogeneration systems at our Mibu Factory (Tochigi Prefecture) and Tsukuba Factory (Ibaraki Prefecture) to actively utilize waste heat. They have contributed to reduce the amount of electricity purchased and fuel consumption used for gas-ﬁred cold/hot water generators, which eventually reduce CO₂ emissions. The estimated annual CO₂ emissions reduction by the cogeneration system in FY2022 is 1,480 tCO₂e at the Mibu Factory (Tochigi Prefecture) and 863 tCO₂e at the Tsukuba Factory (Ibaraki Prefecture).
Consideration for the environment by switching to city gas	By switching the fuel from kerosene and LPG to city gas, we are continuously aiming to reduce CO₂ emissions, and eventually to promote our BCP. Moreover, in the headquarters area, turbo chillers and air-cooled chillers were replaced with city gas-powered chillers and hot- and chilled-water generators. In the Tsukuba Factory, kerosene-powered hot- and chilled-water generators were replaced with city gas-powered ones.
Prevention of compressed air piping leakage	Preventing leakage of compressed air piping reduces the load on the compressor and reduces electricity waste.
Reduction of air compressor pressure	To save power, we have promoted adoption of an emergency stop mode for processing machines in standby time and reduction of air compressor pressure (from 0.62 to 0.6 Mpa).
Suspension of operation of air compressors on holidays	Suspension of operation of air compressors on holidays reduces power consumption by 2,354 kWh/year or approximately 40,000 yen.
Reduction in the number of compressors	At the ROBOCUT Production Department, compressors were installed and operating in both the existing building and the extension, but we decided to carry out air piping connection work. As a result, the two compressors in the extension building were operated alternately, while the two compressors in the existing building were stopped, reducing power consumption.
Reduction of loss due to spoilage	As a result of promoting activities to reduce loss due to spoilage by prioritizing parts with high cost of loss due to spoilage, monthly loss due to spoilage was reduced, greatly contributing to the improvement of management efficiency.
Zero "rust" of machined products	We achieved zero “rust” of machined products in FY2021 by examining cutting materials and utilizing rust-preventive agents.
Reduction of power used for lighting in the workplace	As a measure to reduce power consumption of lighting in the workplace, lighting at the painting robot site was always switched off and only turned on when in use. In addition, lighting in utilities (restrooms, compressor room, and boiler room) was switched to lighting that is compatible with motion sensors. We have promoted energy saving by replacing all lighting in working areas of the Hayato Factory No.1 with LED lighting. The ROBODRILL Production Department has reduced factory electricity consumption by optimizing the lighting of night lights.
Reduction of power consumption in aluminum smelting and holding furnaces	At the injection molding factories in the Headquarters and the Mibu Mold Factory, an insulating jacket is installed on the aluminum smelting and holding furnace used in the die-casting facility to reduce power consumption by suppressing heat radiation. Over the years, the factory has also been contributing to the prevention of heat stroke and burns among workers and the reduction of air-conditioning load.
Reduction of standby power of automated warehouses for parts	To reduce standby power of automated warehouses for parts, we have turned off a crane servo system during non-operation of the warehouses, which has resulted in reducing power consumption by approximately 600 kWh/month since March 2023.
Reduction of cycle time of manufacturing components	We have continued to develop software functions that reduce cycle time of manufacturing components.
Reduction of standby power consumption	In the Sheet Metal Production Department, we have adopted a production system that concentrates production within a one-week period, completely eliminating standby power and reducing standby power consumption.
Suspension of holiday operation	For many years, the Servo Motor Production Department has operated boilers and other equipment on holidays to ensure quality. However, after verifying that there were no problems with quality control, we reviewed our operations and decided to stop operating equipment on holidays.
Space efficiency	We are promoting space efficiency through compactification to accommodate increased production in the robot assembly and testing processes, which require a large work area.
Energy-saving temperature testing equipment	In the Robot Controller Production Department, temperature testing of small controllers is now carried out on a printed circuit board basis, allowing testing to be done using small testing machines. This has eliminated the need for large testing machines, and has resulted in energy savings.

Logistics Initiatives

FANUC contributes to saving energy required for manufacturing products.

Use of truck return trips	The trucks that deliver CNC systems to machine tool builders in Japan are normally empty on their return trips. We are notifying suppliers of the availability of such empty trucks so that they can use them for parts deliveries, thereby improving the efﬁciency of truck operations (reducing the number of trucks) and reducing CO₂ emissions.
Container packing at our factories	In the past CNC systems for export were transported by truck from FANUC to a port warehouse, and were packed into containers in a port area. We have changed the procedure and have installed equipment to ship containers from FANUC factories, so that they can be sent directly to the packing area. This has made it possible to reduce the number of trucks by improving the container loading rate and by replacing trucks with trailers, which have a larger loading capacity.
Improving on-site logistics efﬁciency	Local roads surrounding our Headquarters area used to be congested by trucks to accommodate on-site logistics among the many factory buildings. By improving private on-site roads, we have reduced the use of the local roads, secured trafﬁc routes, and facilitated logistics. In the Mibu Factory, all factories are connected by conveyors, eliminating truck-based transportation within the premises. Tsukuba Factory has eliminated the use of trucks for transport within its premises by increasing the size of the building, and connecting all robot production processes by conveyors within the same building.

Initiatives at Non-production Sites

Installation of solar power generation equipment	Solar power generation equipment has been installed in some of the buildings in our Headquarters area. In FY2022, a total of 37,600 kWh was generated from solar power. We have also installed solar power generation facilities with capacities of 1,750 kW in the headquarters area, 2,814 kW at the Mibu Factory, 30 kW at the Mikawa Service Center, and 20 kW at the Kokura Service Center. In addition, in our Headquarters area, solar power generation equipment with a capacity of 2.4 MW is currently being installed.
LED lighting	We have converted mercury lamps and general-purpose ﬂuorescent lamps (used in our factories and ofﬁces) to LEDs, and also replaced ceiling lights, guidance lights, and emergency lights with LED lighting. In addition to the use of LEDs, motion detectors have been installed in areas where people are not always present, such as corridors and toilets, in order to prevent unnecessary lighting. In the Mibu Factory office, the room is divided into 38 sections, and we use motion and light intensity sensors to prevent unnecessary lighting. The outside lights at the Tsukuba Factory were switched to LED, we have adopted LED lighting for two factory buildings.
Cogeneration system	We have introduced a cogeneration system in our Headquarters area, using waste heat for the welfare facilities in company housing and dormitories, as well as for the hot water supply and heating at FANUC ACADEMY. In FY2022, the estimated annual CO₂ reduction from the cogeneration system was 1,426 tCO₂e.
Building renewal	At our Osaka Branch, we have renovated the entire building, with only the framework left in place, and introduced energy-saving air-conditioners, LED lighting, and motion detectors. We have reduced air-conditioning power consumption by 60% and total power consumption by 40%.
Demand response	In response to a request from the power supply company, we conduct, so-called Negawatt Transactions, to reduce power consumption when the power supply and demand are expected to be tight.
IT infrastructure	By turning off PC monitors during breaks, estimated annual power savings is expected to total 28,800 kWh.
Enhancement of building insulation	To reduce the amount of energy used for heating and cooling, we have introduced various measures to enhance insulation, such as external and internal insulation, double-wall (double-skin) construction for external walls, condensation-proofing, and the use of double-glazed windows. Double-skin walls have been adopted in the parts center building of the Hino Branch Office and in the Nagoya Service Center. For company housing built in 2017 or later, we are working to build facilities with the aim of obtaining a rating of B+ to A (self-assessed) in the Comprehensive Assessment System for Built Environment Efficiency (CASBEE), by actively introducing external insulation and double-glazed windows.
Improvement of service efficiency	We have reduced time required for service by expediting procedures for service calls and emails with two-dimensional codes attached to end users’ machines and using photos and videos.
Expansion of sale of new products with functions that contribute to environment	We have expanded sale of new products with functions that contribute to environment and promoted a shift to new CNCs.