Lean Energy Conservation Program

Transcription

1 Lean Energy Conservation Program

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3 Why create a Conservation Program? We spent over 6 millions a year on fuel and electricity in our facility. Energy is a commodity which we cannot afford to waste and affects everyone of us. Fuel costs have increased considerably over the last five years. Saving energy makes environmental and good business sense. Cultivate the mindfulness of our colleagues. Continuous Improvement initiatives.

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5 LPO s Energy Policy

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7 LPO Energy Custodian Team (ECT) Main Purpose: Change the culture and people s mind set within the organization Engage all level of our organization Helps drive the Lean Energy Program Two main sub-committees Technical subcommittee - composed by persons with strong technical background to help drive the implementation of the projects Steering subcommittee - helps guide the activities of the energy management program and aids in communications through all organizational levels.

8 Teamwork Makes the Difference!

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10 Structures LPO Lean Energy Methodology LPO Governance & Leadership Engagement Information Gathering Monitoring & Feedback Assessment Management Directive Building The Plan TC : Training Council BRC #4: Projects QRC Quality Metrics LPO Governance BRC #3: Business Metrics BRC #1: S&OP months BRC #2: New Products Implementation %7,385,703.

11 Other tools used Continuous Improvement Methodology (SIP) Lean Six Sigma Flowcharts Financial Analysis Usage Daily Monitoring SWOT Analysis ECT Monthly Meetings

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13 Warehouse and Parking Lighting Retrofit Warehouse Before Warehouse After Savings: KWh Before: KWh After: 1,158,422 KWh/year 621,813 KWh/year

14 Boiler Control System Savings: Fuel Before: 1,274,000 Gal/year Fuel After: 1,231,000 Gal/year KWh Before: 174,000 KWh/year KWh After: 67,000 KWh/year

15 Solar Water Heaters Farm Expected Savings: Yearly savings: 11,000 gal/year Aprox: $40,000 per year

16 Other initiatives Power Factor Correction for Air Compressor #2 Non Essential Air Conditioning System Shut-off Schedule Preventive Energy surveillance by Security Officials and ECT Lighting Timers & Motions Sensors Installation Two 200 HP VFD of the Chiller Water Secondary Pump were repaired In-house Infrared Inspection Compressed Air System Assessment Clean Rooms re-classification Steam Traps Assessment

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18 Two Years Results $0.200 $0.190 $0.191 $3.60 $3.30 $3.46 $0.180 $3.00 $0.170 $0.160 $0.150 $0.140 $0.141 $0.151 $0.158 $2.70 $2.40 $2.10 $1.80 $1.65 $1.97 $2.41 $0.130 $1.50 $ Projected* $ Projected* $/KWh $/Gallons 30,000,000 29,277,609 1,200,000 29,000,000 1,100,000 1,062,571 28,000,000 27,000,000 26,000,000 25,000,000 26,822,400 25,238,400 1,000, , , , ,039 24,000, ,000 23,000, , KWh Gallons of Diesel Increase in Manufacturing Volumes

19 Combined Savings Electricity Fuel $4,700,000 $2,700,000 $4,500,000 $2,500,000 $4,300,000 $2,300,000 $4,100,000 $2,100,000 $3,900,000 $1,900,000 $3,700,000 $1,700,000 $3,500, $1,500, Without any Improvement Actual Without any Improvement Actual $1.0MM, 2yrs Savings $834k, 2 yrs Savings

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21 Some benefits are Direct Benefits Economic Environmental Indirect Benefits Enhanced public image Use of new technologies Team Building and Team Awareness Extended equipment life Reduced maintenance costs Reduced risk to energy supply price spikes Reduced risk to environmental/legal costs

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23 Sustainability tools SP Global and Local Energy Policy Plant Goals and Objectives (PMP s) Management Commitments Power Logic Monitoring System Department Staff meetings Monthly Metrics Lean Energy Guidelines

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25 Rising awareness & Effective communications Energy Tips Brochure Energy Conservation Program Logo Monthly energy computer banners Awareness Stickers Awareness posters Intranet News and Projects Presentations New employees/contractors orientation Logo affixed to Plant Uniforms el 91, e 19 ush, d re ge B r mb a ptie s Geo s de l e s o e e d i d m n l 3 e 1 os U mo?, el que Estad bre co RGIA d e s E t u o oct s l N u! e a gía la E bía ed ner Sa ident clamó sobre e r s orra Pre re, pro ación z a ah a pad cienti z pie con em y ete Ún

26 Change a Light Change the World A Compact Fluorescent Lamp (CFL) give away as part of the Energy Star campaign

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28 Pioneers within our Company Based on our policy and success, Global SP has been using LPO as a benchmark and example for other sites Support deployment and implementation of the SPARC (SP Action for Resource Conservation) program Three Certified Energy Managers (CEM) by the Association of Energy Engineers (AEE) LPO Energy Custodian Team makes the difference

29 2007 Environmental Achievement Award for Energy Excellence

30 Contact person: Luis Bosques Phone: