integrating sustainability to lean-out daily operating ... · pdf fileintegrating...

Presented by: Douglas Kessler, Vice President

Integrating Sustainability to Lean-out Daily Operating Programs and

Standards

© 2011 Roy Jorgensen Associates, Inc.

What is right for you

Understanding early decision impacts

Life cycle costs of an asset

Long-term environmental impact

Decision-making tools for ‘greening’ daily operations

Plan: Sustainability Assessment, Expense Review

Do: Sustainability Service Level Decision-making Tool, LEED EB in Daily Operations Tool, Project Justifications

Check: Measurement & Verification

Act/Study: Expense Review, Quality Control

2 © 2011 Roy Jorgensen Associates, Inc.

Certified or Certifiable


Service Levels and Scope

Scope

Se

rvic

e L

eve

l“Best-in-Class”

True Green

Light Green

Green Wash

Traditional Methods

“Best Practice”

Scop

e an

d Se

rvice

Leve

l opt

imized

for th

e or

ganiza

tion

Integrated Paractices

Core Competency

Lean Thinking

Single Facility / Single Point


Organization Goals &

Objectives

Total Life Cycle Cost

Long-Term Cost of Point

Systems

Asset Replacement Opportunities


Change the fundamental maintenance & operations

Create a comprehensive, strategic Program


Sustainability Decision-Making Tools

PLAN

- Sustainability Gap Analysis - Cost Review

DO

ACT/ STUDY

CHECK

- Sustainability Service Level Decision-making

- Project Justifications/ Business Case

- Bill of Materials Review - Quality Control

- Measurement & Verification


Strategic Assessment

Establishing quantifiable metrics

Documentation for all management plans

Feature asset inventory

Refrigerant management plan & inventory

Emissions reporting: CO2, SO2, NOX.

IAQ management plan

Sustainable purchasing plan

Solid waste plan

Occupant comfort surveys


Account Name Annual Cost

Audio Visual Supplies $76

Parking Lots/Garages $240

Exp Prjs - Janitorial $350

Small Appliances $1,509

Elevator Maintenance $2,380

Exterior Building Mtce $2,380

Vandalism Incidents $3,927

Expensed Equipment $3,942

Discretionary Reserve $6,063

Plumbing $6,415

R&M Facilities $7,984

Pest Control $12,612

Priority Projects $17,524

Speciality Cleaning $18,285

Exp Prjs - R&M Facilities $19,168

Electrical $20,230

Natural Gas Utility $22,902

R&M Equipment $24,887

R&M HVAC $32,036

Fire Life Safety $37,453

Janitorial Supplies $45,747

Waste Mgmt $50,730

Water Utility $98,324

Landscaping $133,751

Janitorial $325,495

Electric Utility $724,972

Grand Total $1,619,381


ls

Background: Maintenance Service Levels

Reliability-

centered

Maintenance

“Pro-active”

Predictive

Maintenance

“ Condition-based”

Preventive

Maintenance

“Time-based”

Reactive

Maintenance

“Run-to-fail”


Reliability-

centered

Maintenance

“Pro-active”

Predictive

Maintenance

“ Condition-based”

Preventive

Maintenance

“Time-based”

Reactive

Maintenance

“Run-to-fail”

Sustainability Toolbox


Environmentally friendly bill of materials and consumables

14

Procurement standards to minimize use of hazardous materials and chemicals


Component vs. System Level Decision

Leverage your CMMS/

ERP

Focus the Lean

Sustainability practice at

the lowest level of the

asset hierarchy that

makes economic sense


The Corporation

Enterprise

Toyota

USA

Facility / Plant

Headquart

ers

Cam

pus

Geographic Location

Unit / Platform

Data

Cente

r 1

Production Enity

System

Cooling P

lant

Top-Level Function

Subsystem

Condenser

Pum

p N

etw

ork

Subordinate Function

Group

Moto

r – P

um

p A

ssem

bly

Functional Assembly

Component

Pum

p

Equipment

Assembly

Impeller

Multiple Parts

Identifiable by Part Number

Bearing

Part

DO: Life Cycle Cost Analysis ?

16

1. Define Problem and State Objective

2. Identify Feasible Alternatives

3. Establish Common Assumptions and Parameters

4. Estimate Costs and Time of Occurrence for Each Alternative

5. Discount Future Costs to Present Value

6. Compute and Compare LCC for Each Alternative

7. Compute Supplementary Measures if Required

for Project Prioritization

8. Assess Uncertainity of Input Data

9. Take Into Account Effects for

Which Dollar Costs or Benefits

Cannot be Estimated

10. Advise on the Decision


ACT/STUDY: Quality Control

Audit of Janitorial Chemicals and Paint Specifications

Client: TFS for CSCC facility

Report date: 2/9/10 through 5/11/10

Introduction

Summary of Audit Results

Recommendations for Next Steps

* 16 janitorial supplies are OSHA regulated and we need to confirm that proper personal protection equipment

and procedures are being used

* Identified two items that are carcinogenic and one product that may cause reproductive harm. Recommend

high priority for alternatives.

(1) Review paint specifications for more environmentally friendly alternatives

* 16 items were either no longer available or unable to be found on the internet. Need to verify MSDS sheets.

* 13 janitorial supplies have pH levels equal to or greater than 12.5 and should be reviewed for less acidic

alternatives

Audit was conducted between February and May 2010 and included all janitorials supplies and paint

specifications for TFS's Customer Service Center in Cedar Rapids, IA. In total, Jorgensen reviewed 97 janitorial

supplies, two paint specifications, and one glue specification.

* One paint specification does not meet Green Seal or SCAQMD standards

* Six janitorial supplies are currently on Green Seal's certified products list

* Only 9 out of 97 janitorial supplies had current MSDS sheets on file

XXXXXXXXXXXXXXXXX

XXXXXXXXXXXXXXXXXXXXXXXXXXXXX


Account Name Annual Cost

Audio Visual Supplies $76

Parking Lots/Garages $240

Exp Prjs - Janitorial $350

Small Appliances $1,509

Elevator Maintenance $2,380

Exterior Building Mtce $2,380

Vandalism Incidents $3,927

Expensed Equipment $3,942

Discretionary Reserve $6,063

Plumbing $6,415

R&M Facilities $7,984

Pest Control $12,612

Priority Projects $17,524

Speciality Cleaning $18,285

Exp Prjs - R&M Facilities $19,168

Electrical $20,230

Natural Gas Utility $22,902

R&M Equipment $24,887

R&M HVAC $32,036

Fire Life Safety $37,453

Janitorial Supplies $45,747

Waste Mgmt $50,730

Water Utility $98,324

Landscaping $133,751

Janitorial $325,495

Electric Utility $724,972

Grand Total $1,619,381


Future Steps

Illustration derived from NACUBO’s “Managing the Facilities Portfolio: A Practical

Approach to Institutional Facility Renewal and Deferred Maintenance”, 1991 p. 6

Facility Inspection

Short- Range &

Long-Range Needs

Funding Alternatives

Decision Stake

Holders

The “Tradational” Maintenance Cost Considerations

The “New” Paradigm Includes Sustainable

Maintenance Concepts

Integration Sustainability and Long-term Expense Impacts into FCAs


Summary

Alignment With Corporate Directions


So this is really all about being selective about what is right for your individual organization’s goals and objectives

Be sure to understand what the true long-term cost of a point system decision can have

Look beyond the single facility and integrate your sustainability efforts across the entire portfolio

Understand the total life cycle cost analysis of each decision – adjust service levels and consider asset replacement opportunities


Key Elements

Presented by: Douglas Kessler, Vice President


Integrating Sustainability to Lean-out Daily Operating Programs and

Standards

integrating sustainability to lean-out daily operating ... · pdf fileintegrating...

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