MILFORD ENERGY KAIZEN

Transcription

1 MILFORD ENERGY KAIZEN J E F F W I L S O N S C H I C K W I L K I N S O N S W O R D M I L F O R D C O N N E C T I C U T PRESENTATION OBJECTIVE Provide the Milford facility energy footprint and conservation history Explain the decision to utilize a kaizen event for conservation Highlight Kaizen event details Review the event results and follow up activity Present recommendations for other facilities considering a similar effort 1

2 MILFORD FACILITY Production, RD&E and Operations HQ Building has been operating since 1961 Multiple Expansion, double the size Shifts - from 3 shift to 7 day schedule 425,000 square feet Key Processes Blade Making Injection Molding Assembly ENERGY FOOTPRINT Annual Energy Use 38,000,000 kwh Electrical 58,558 MMBtu Thermal (Natural Gas) Energy Breakdown Natural Gas 29% Energy 7% Cost Electricity 71% Energy 93% Cost 2

3 CONSERVATION HISTORY More than 75 conservation projects have implemented in the Milford Plant since the early 1990s Reduction in over 3,000,000 kwh over the past three years Strong partnership with United Illuminating Utilize incentives to develop and justify projects Leverage engineering for new processes and facility expansion PROJECT FOCUS Conservation project focus on generation systems, building envelope and environmental controls HVAC Systems Chilled Water Systems Steam System Compressed Air Supply Lighting 3

4 ENERGY KAIZEN INITIATION United Illuminating expressed strong interest in piloting a Kaizen event. Good fit for our facility Conservation at Schick was owned by a small group of engineers Opportunities for improvements were becoming scarce Availability of a resource with Energy Kaizen experience and familiarity with our organization and facility EVENT FORMAT Introduction, goal setting, consultant selection Baseline measurements Identify Kaizen team Training Sleeping Plant Investigation Report Out Implementation 4

5 KAIZEN GOAL Reduce energy usage by a specific percentage Develop short to medium term project list Educate key colleagues in conservation Create a team of experts to draw on for Behavioral Based Conservation Support for production department projects Provide skills for calculating impact of design and production decisions BASELINE MEASUREMENTS Multitude of measurement devices were utilized Occupancy sensors with lighting triggers Flow Meters Combustion analyzer Infrared thermometer Multimeter Soap and Water Ultrasonic 5

6 KAIZEN TEAM One Large Team Multi Disciplined-Engineers, Trades, Lean Techs Internal and External Resources Production department representation Seasoned trades and apprentices 4 Sub Teams based on measurement, opportunity and expertise Motors Lighting Compressed air HVAC and Boilers KAIZEN TEAM Team 1 Lighting Team 2 HVAC/Boilers Team 3 Motors and Machines Team 4 Compressed Gas Brian Rosiak Carey Reeves Ted Novicki Frank Mazzara CT Controls Mike Kosiewicz Wilfredo Morales Doug Stevenson - LEA Don Weaver Bruce Beckmann Herlan Pedron Lenny Caudill Joe Rennie Albert Aponte Jeff Wilson Jim Atwood Tom Zola 6

7 TRAINING All team members were trained in the following: Kaizen format Value added vs. Non value added work Identifying opportunities Measurement devices Calculations Available technologies Energy cost The 4 sub teams were also given training specific to their focus SLEEPING PLANT Questioned the benefit with a 24/7 operation, but it served to be valuable to: Assemble the group without distraction Kick off the event Apply principles of sleeping plant to areas that might be idled Continue to teach team members with minimal conservation experience Focus on processes 7

8 MAIN INVESTIGATION Took place over a 2 day accelerated time period Identified non-value added energy use Follow up to many sleeping plant findings Measured and quantified use Identified available technologies for reduction or elimination Corrected deficiencies as applicable Examples are compressed air leaks and stuck dampers Expand findings Determine the magnitude of reductions REPORT OUT A master spreadsheet with opportunities and annual savings This document drives the follow on activity Presentation was created for operations management Each significant opportunity was detailed on a page 8

9 OVERALL RESULTS Savings $589, Kaizen Opportunities Cost $287,000 Payback 0.49 Years RESULT DETAILS Kaizen Event - Energy Savings MMBTU 16,106 12,037 KWH 4,720,537 3,527,957 Total MMBTU 28,144 % Reduction - Energy 13.9% Kaizen Event - Cost Savings Electrical Savings Natural Gas $ $ 432, ,852 Nitrogen $ 27,764 Total Savings $ 589,322 % Reduction - Energy cost 10.5% 9

10 LESSONS LEARNED Good Energy Generation Systems opportunity is now efficient use Plenty of shut-it-off opportunities no-value-add, no cost! Need to leverage existing energy management systems Workforce receptive to energy savings ideas just need to raise awareness of $$ Cultural change will provide big $$$ Energy conservation is a continuous process that requires planning/resources and ownership to be sustainable RECOMMENDATIONS Identify and utilize a qualified consultant Assemble a team that is designed to meet the goals of the event and longer term strategy Utilize measurements to drive the event Do not underestimate the importance of the training Focus on key areas instead of solving every issue Plan on follow up kaizens 10

11 QUESTIONS? J E F F. W I L S O E N E R G I Z E R. C O M