energy kaizen: strategic energy productivity · pdf fileenergy kaizen: strategic energy...

22
Energy Kaizen Proprietary Information Waste Lean TOC 6 s Energy Kaizen: Strategic Energy Productivity Improvement

Upload: vankhanh

Post on 07-Feb-2018

267 views

Category:

Documents


7 download

TRANSCRIPT

Page 1: Energy Kaizen: Strategic Energy Productivity  · PDF fileEnergy Kaizen: Strategic Energy Productivity Improvement . Energy Kaizen

Energy Kaizen Proprietary Information

Waste

Lean

TOC 6 s

Energy

Kaizen:

Strategic

Energy

Productivity

Improvement

Page 2: Energy Kaizen: Strategic Energy Productivity  · PDF fileEnergy Kaizen: Strategic Energy Productivity Improvement . Energy Kaizen

2 Energy Kaizen Proprietary Information

Waste

Lean

TOC 6 s

Schedule

PCC History

Customers: Boeing, GE, Pratt Whitney, Airbus

Sectors: aerospace, power generation, medical, general industrial

Divisions: castings, forgings, fasteners

1955-2005: $0-3B annual revenue

2005-2010: $3-6B annual revenue

Very decentralized organization (108 plants)

Page 3: Energy Kaizen: Strategic Energy Productivity  · PDF fileEnergy Kaizen: Strategic Energy Productivity Improvement . Energy Kaizen

3 Energy Kaizen Proprietary Information

Waste

Lean

TOC 6 s

Schedule

Nick Balster History

BS MS&E, University of Wisconsin

MBA, Babson College (in-process)

Hired by PCC in 2000

Operations, technical roles within PCC

4 business units, 3 plants, 2 countries

Corporate Energy Manager since 2008

Page 4: Energy Kaizen: Strategic Energy Productivity  · PDF fileEnergy Kaizen: Strategic Energy Productivity Improvement . Energy Kaizen

4 Energy Kaizen Proprietary Information

Waste

Lean

TOC 6 s

Agenda

Introduction to Energy Kaizen

Treasure Hunt Model

Areas of focus

Large Plant Focus

SPS-Jenkintown: UE (Waetjen) Introduction

SMC-Huntington: years of focus

Conclusions

Page 5: Energy Kaizen: Strategic Energy Productivity  · PDF fileEnergy Kaizen: Strategic Energy Productivity Improvement . Energy Kaizen

5 Energy Kaizen Proprietary Information

Waste

Lean

TOC 6 s

Schedule

Energy Kaizen Event History

2007: pilot at largest plant (external consultants)

2008: program built on pilot; internalized

2008: corporate-wide program begins

2009: 32 events completed; $4.2M implemented savings

2010: resource additions to bolster programs

2011: energy team developed to drive further savings

2012: energy department planned to continue internalizing

Page 6: Energy Kaizen: Strategic Energy Productivity  · PDF fileEnergy Kaizen: Strategic Energy Productivity Improvement . Energy Kaizen

6 Energy Kaizen Proprietary Information

Waste

Lean

TOC 6 s

Schedule

Energy Kaizen Event Schedule

Overview presentation

Plant tour

Goals/expectations review: energy productivity

Review of energy users: asset list

Review of QuickPEP results

Utility bill review: meet with our friends at the utilities

Treasure Hunt: tag leaks, log, maintenance work order placement

Reflection session: energy board

GM Staff Presentation

Page 7: Energy Kaizen: Strategic Energy Productivity  · PDF fileEnergy Kaizen: Strategic Energy Productivity Improvement . Energy Kaizen

7 Energy Kaizen Proprietary Information

Waste

Lean

TOC 6 s

Schedule

Treasure Hunt

Asset list – write down any missing data (kW, HP, etc.)

Discuss usage with operators

Evaluate for shutdown procedures (shift, weekend, shutdowns)

Reflection meetings

Quantify savings opportunities

Page 8: Energy Kaizen: Strategic Energy Productivity  · PDF fileEnergy Kaizen: Strategic Energy Productivity Improvement . Energy Kaizen

8 Energy Kaizen Proprietary Information

Waste

Lean

TOC 6 s

Data Collection

Treasure Hunt Ground Rules

Ratio FY11 forecast to FY12 forecast: use ratio as a guide

Brainstorm ‘likely suspects’: NG, process gases, CA, electricity

Asset list: touch every piece of equipment

Need average numbers/hour

Determine sizes of all leaks; write tags

Collect all forms of energy waste (lights left on, motors running,

pumps, blowers, compressors, etc.) – document

Page 9: Energy Kaizen: Strategic Energy Productivity  · PDF fileEnergy Kaizen: Strategic Energy Productivity Improvement . Energy Kaizen

9 Energy Kaizen Proprietary Information

Waste

Lean

TOC 6 s

Energy Waste: Examples

Compressed Air Leak

(Process Defect)

Steam Leak

(Process Defect) Water Spills

(Over Processing)

Excess Fuel Usage

(Motion, Over Production, Transportation)

Page 10: Energy Kaizen: Strategic Energy Productivity  · PDF fileEnergy Kaizen: Strategic Energy Productivity Improvement . Energy Kaizen

10 Energy Kaizen Proprietary Information

Waste

Lean

TOC 6 s

Energy Waste: Examples

Poorly functioning HVAC

Water Leak

Waste Heat Release

Inefficient Lighting

Page 11: Energy Kaizen: Strategic Energy Productivity  · PDF fileEnergy Kaizen: Strategic Energy Productivity Improvement . Energy Kaizen

11 Energy Kaizen Proprietary Information

Waste

Lean

TOC 6 s

Energy Waste: Examples

Compressed Air Intake Indoors

Bare Piping

Poor Air/Fuel Ratio

Inefficient Motors

Page 12: Energy Kaizen: Strategic Energy Productivity  · PDF fileEnergy Kaizen: Strategic Energy Productivity Improvement . Energy Kaizen

12 Energy Kaizen Proprietary Information

Waste

Lean

TOC 6 s

Some Examples Of Energy Waste

Machines left running when not in

operation

Running oversized motors

Running motors beyond optimum load

requirement

Using more than minimum air pressure

to operate machinery

Oven or freezer temperatures are set

above/below optimum

Lack of shutdown procedures

Excess assets in downturns (% basis)

Employee control of temperature

settings

Lighting not controlled by motion

sensors

Poor maintenance & work methods

Lack of formal system to track energy

usage/waste

Lights left on

Machines left on during breaks

Lack of communication on energy spend

Page 13: Energy Kaizen: Strategic Energy Productivity  · PDF fileEnergy Kaizen: Strategic Energy Productivity Improvement . Energy Kaizen

13 Energy Kaizen Proprietary Information

Waste

Lean

TOC 6 s

Prioritize – Death by a Thousand

Paper Cuts

3

3

5

5

9

9 EASE

IMP

AC

T

1

2

3

4

5

6

7

8

9

10

12

Page 14: Energy Kaizen: Strategic Energy Productivity  · PDF fileEnergy Kaizen: Strategic Energy Productivity Improvement . Energy Kaizen

14 Energy Kaizen Proprietary Information

Waste

Lean

TOC 6 s

Agenda

Introduction to Energy Kaizen

Treasure Hunt Model

Areas of focus

Large Plant Focus

SPS-Jenkintown: UE (Waetjen) Introduction

SMC-Huntington: years of focus

Conclusions

Page 15: Energy Kaizen: Strategic Energy Productivity  · PDF fileEnergy Kaizen: Strategic Energy Productivity Improvement . Energy Kaizen

15 Energy Kaizen Proprietary Information

Waste

Lean

TOC 6 s

Large Plant Focus

SPS-Jenkintown ($2-3M annual spend); 2008

Largest fastener plant in PCC

Aerospace bolts, nuts, pins

1000s of machine tools

Whole plant assessment; little experiences with energy

Team of 6

Page 16: Energy Kaizen: Strategic Energy Productivity  · PDF fileEnergy Kaizen: Strategic Energy Productivity Improvement . Energy Kaizen

16 Energy Kaizen Proprietary Information

Waste

Lean

TOC 6 s

Large Plant Focus

SPS-Jenkintown: 3-day Event

Compressed Air Systems

UE introduction to PCC

Lighting systems

Motors and drives

PLC controls

Demand Response

$363k annualized

savings implemented

to date

Page 17: Energy Kaizen: Strategic Energy Productivity  · PDF fileEnergy Kaizen: Strategic Energy Productivity Improvement . Energy Kaizen

17 Energy Kaizen Proprietary Information

Waste

Lean

TOC 6 s

Some Examples from the Field

Page 18: Energy Kaizen: Strategic Energy Productivity  · PDF fileEnergy Kaizen: Strategic Energy Productivity Improvement . Energy Kaizen

18 Energy Kaizen Proprietary Information

Waste

Lean

TOC 6 s

Large Plant Focus

Special Metals-Huntington ($20-25M); 2007 start

Combustion Systems

Compressed Air Systems

Lighting systems

Motors and drives

PLC controls

Demand Response

$2,265k annualized

savings implemented

to date

Page 19: Energy Kaizen: Strategic Energy Productivity  · PDF fileEnergy Kaizen: Strategic Energy Productivity Improvement . Energy Kaizen

Energy Kaizen Proprietary Information

Waste

Lean

TOC 6 s

Sustain the Gains

Page 20: Energy Kaizen: Strategic Energy Productivity  · PDF fileEnergy Kaizen: Strategic Energy Productivity Improvement . Energy Kaizen

20 Energy Kaizen Proprietary Information

Waste

Lean

TOC 6 s

Management Reviews: MBWA

Conducted Twice Monthly:

TBD at TBD am/pm

TBD at TBD am/pm

Objective:

Senior management debriefing and audit of process

Direct communications between senior management and operators

Communicate & recalibrate priorities, consensus on focus

Format:

Standing meeting 10 to 15 minutes maximum

Not a problem solving session. Assign responsibility for follow-up if necessary.

Agenda:

Latest usage data and trend versus target.

Standard Procedures Updates

Kaizen Newspaper Activity

Page 21: Energy Kaizen: Strategic Energy Productivity  · PDF fileEnergy Kaizen: Strategic Energy Productivity Improvement . Energy Kaizen

21 Energy Kaizen Proprietary Information

Waste

Lean

TOC 6 s

Empowerment

Electricity

Turn off all air blowoffs and air knives when your machine is not running (even if it's only a few minutes)

Turn off machine motors when not in use (Ex: Rollers, scrap and work conveyors)

Disconnect air tools from air line when not in use.

Immediately report air leaks to your supervisor, no matter how small.

Turn off shop lights when an area will be unoccupied for at least an hour (Ex: Maintenance, CNC department, sorting)

Turn off office lights if room is not in use.

Avoid jogging multiple headers at once to reduce peak usage penalty (Will require operator awareness and teamwork)

Turn off work lights when not in use (Ex: Work lights in header die areas)

Use power saver features on office equipment (printers, monitors, etc) and turn off computers and printers at night.

Do not remove, alter, or discard energy efficient devices without supervisor permission (Ex: Nozzles on blowoffs)

Replace inefficient space heaters with energy efficient models

Turn off General Drive air compressor immediately at end of shift.

Gas

Never turn office thermostats above 68 degrees.

Lower temperature on office thermostats to 60 degrees when leaving for the night (Last person out).

Turn on shop heaters only when absolutely necessary.

Close all outside doors when heaters are in use.

Water

Use oil skimmers on parts washers to prevent water contamination

Report any leaky or defective plumbing to your supervisor.

TIPS - Utility Cost Reduction

Page 22: Energy Kaizen: Strategic Energy Productivity  · PDF fileEnergy Kaizen: Strategic Energy Productivity Improvement . Energy Kaizen

22 Energy Kaizen Proprietary Information

Waste

Lean

TOC 6 s

You can do it

Conclusions

Any organization can successfully implement this, if:

YOU make energy a priority

YOU are passionate about improving productivity

Recommendations

Contact your utilities – rates

Run your organizations numbers