kitchener chamber of commerce's 2013 energy and environment conference
DESCRIPTION
Overview of a SME achieving 3P initiatives.TRANSCRIPT
Energy and Environment
•People•Planet•Profits
1. Our products-Consumer & Commercial2. Our corporate strategy3. Our local strategy
“A society grows great when old men plant trees whose shade they
know they shall never sit in.”(Greek Proverb)
Building supply dealers & big box stores
Advantage ICF System®Insulated Concrete Forms
EIFS-Exterior Insulated Finishing Systems
• Show insulspan job site sign
Insulspan-Structural Insulating Panels
CORPORATE SUSTAINABILITY
From a focus on promotionof benefits towards ….
Internal sustainability andexternal transparency
Sustainable Materials and Processes
Measurement and Reporting
Manufacturing Initiatives
Transparency
Become recognized for your actionsnot just your words.
Transition to Sustainability
Setting Targets for Improvement
Reduce energy consumptionReduce waste outputReduce emissions to the environment
Sustainability - Journey of Continuous Improvement
Continuous improvement implies a process without end
Similar to other continuous improvement processes– Lean Manufacturing– ISO– Six Sigma
Identify, measure, set targets, implement action, measure, analyze and set new targets/actions
PFB’s Sustainability CommitteeSustainability Committee
Chair
Economic Sub- Committee
Product Sub-Committee
Employees Sub- Committee
Environmental Sub-Committee
Product Responsibility
-Product use & end life issues
-Digital Information
-Packaging & labeling
Human Rights & Labour Practices
-Employee Involvement
-Social Responsibility
-Training
-Policy development
-community Outreach
Environmental Performance
-Lean Manufacturing
Resource Utilization
-Emissions
-Energy Utilization
Economic Performance
-Project Analysis & Justification
-Risk Analysis
-Annual Report
Scrap EPS Waste-one man’s trash is another man’s gold!
Scrap EPS Waste
Why is scrap EPS foam sent to landfill/recycling a problem?– Its worth something, EPS waste = $
• Energy to produce the material• Transportation to recycling• Manpower to move and load it• Space to store it
Poor image to portrayNot consistent with sustainability2012 Kitchener used 400,000 lbs of regrind
Plant Level Initiatives
Sustainable Lean Manufacturing
Energy & Environment
1.Electricity
2. Natural Gas
3. Water
4. Secondary Fuels
Waste Type Examples Environmental ImpactsDefects Scrap, rework, replacement production,
inspection-Raw material consumed in making defective products-Defective components require recycling or disposal-process energy-More space required for rework and repair, increasing energy used for heating, cooling and lighting
Waiting Stock-outs, lot processing delays, equipment downtime, capacity bottlenecks
-Potential material spoilage or component damage causing waste-Wasted energy from heating, cooling, and lighting during production downtime
Overproduction Manufacturing items for which there are no orders
-More raw material consumed in making unnecessary inventory-Extra products that may spoil (damage) or become obsolete requiring disposal-Extra hazardous materials used result in extra emissions, waste disposal, worker exposure
Motion/Transport Human motions that are unnecessary or straining, carrying WIP long distances, transportationExcess transport of WIP or products
-More energy use for transport-Emissions from transport-More space required for WIP movement, increasing lighting, heating and cooling demand and energy consumption-More packaging required to protect components during movement-Damage and spills during transport-Transportation of hazardous materials requires special packaging to prevent risks during accidents
Inventory Excess raw material, WIP, or finished goods -More packaging to store WIP-Waste from deterioration or damage to store WIP-More materials needed to replace damaged WIP-More energy used to heat, cool and light inventory space
Over processing More parts, more process steps, or time than necessary to meet customer needs
-More parts and raw material consumed per unit of production-Unnecessary processing increases waste, energy use and emissions
Unused Creativity Lost time, ideas, skills, improvements, and suggestions from employees
-Fewer suggestions for pollution prevention and waste minimization opportunities
Sustainable Lean Manufacturing-TPS
Source: EPA “Environmental Guide to Lean” August 2009 Report
• 2010 – Insulated facility– Installed contactors and light switches– OEE (overall equipment effectiveness “efficiencies”)-Lean manufacturing
• 2011 – New programmable high efficiency boiler– Replaced 30 x 400w metal halide with T8/T5
• 2012– Replaced 25 T12 lights with T8– Replaced 25 x 400w metal halide with T8 and motion sensors– Replaced 18 x 400w metal halide with T5– Changes to regrind system – used over 400,000 lbs. of material
• 2013– Replaced cutting system power supplies with high efficiency power supplies– Further changes to regrind system, to capture 95% of scrap material produced
Energy Saving Projects
Warehouse lights are off most of the time
Lights with sensors Turn off after 10 minutes
Recovered energy-diverting regrind from scrap…cost $3000, material/energy savings of $10,000/yr.
1. old system
2. old system
2.new system
1.new system
Lights w/sensor or illuminated switches for on/off use
Reverse Osmosis System
-Kitchener’s hard water drives up operational costs for process equipment such as boilers
-This has a negative effect on energy consumption due to constant “blow down”
-Equipment ROI is slow- Better option than increasing
CO2 - Better option then reducing
boiler life
The value of Continuous Improvement with sustainable manufacturing
1st reduction from lean activities
2nd reduction from electrical & boiler replacement
3rd reduction
from electrical changes & R/O system
• 2009 vs. 2012• -24 % electricity - $28,000 per year• -22 % H2O - $4,000 per year• -17 % NG - $30,000 per year
• CO2 reduction of 22 % per year• With a 20% increase in production!
– Without changes to energy usage we would have added $68,000 to our operating cost
• Total 2012 energy savings (including cost avoidance) ….$130,000
Reductions & Savings
Reduce, Substitute or Eliminate Methodology
While not directly specific to energy reductions, other little
things add up quickly!
Lift trucks- Pick the right equipment
Recycle oil-Compressor oil/water filter
System stores oil Filter sent out for recycling
• 2009: 102,750
• 2010: 94,454
• 2011: 85,017
• 2012: 83,063
• 2013: 79,800
• On track for a total reduction of 29%
Average Monthly Kwh consumption
• Energy– Lights – approx. 200 old T12 to replace– Motors – approx. 50 to be exchanged to energy efficient models– Compressor - VSD– Enernoc – DemandSMART response program
• Environment– Reusable/recyclable material programs-Waste EPS regrind– Launch oxo biodegradable wrap – Toxic Reduction Act
• Process Equipment– VOC reduction with new process equipment
Future Sustainability Projects
THANKS!
Questions?
• http://www.sustainableplant.com/– Great corporate tools
• http://www.emccanada.org/group_spaces/energy– Excellence in manufacturing
• http://cme.binaryoak.com/– Info about TRA Ontario
• http://www.greenpoweraction.com/business/BusinessCarbonOffsetCalculator.aspx– Calculate your carbon footprint
• https://saveonenergy.ca/Business.aspx– Financial programs
Resources