Energy Performance Contract (EPC) by ESCO Pilot Projects using the Facilitation Approach At Team Date : Nov 17, 2015
Today Agenda 1. TP s Profile 2. Energy Expense Background Year 2012-2014 3. Team Energy Saving Approach 4. ESCO Projects Organization Chart 5. ESCO Project Timeline By Facilitation Approach 6. Project Follow up and Preliminary Energy Audit 7. Energy Breakdown of Utilities and Process Machine 8. Energy Conservation Measures For ESCO Projects
1. Profile : Our Vision To be customers first choice as the best in Class Global Electronics Manufacturing Solutions Provider - your strategic global partner We emphasis on Long Term Relationship - More than 50% of our customers is working with us for more than 10 years
Our Quality Policy Team aim to produce the good quality products Meet Customer Requirements and On Time Delivery conduce to customer Satisfaction by concept of quality improvement to maintain of Excellence Quality standard and Safety of Products including contribution of customer s trust that are continue improvement practice to Achieve World Class Organization. 5
Milestone of Achievement 1990 : 1st 2.5K sqm Factory in Rangsit (TPR) 1994 : Export to Int l Markets 1996 : 2nd 5K sqm Factory in Prachinburi TPP) 1998 : Became CFC Free : Certified ISO9002 2000 : Start DFM & COB 2011 : Bronze Award for Zero Accident Award : National Award for Excellence Safety, Sanitary and Environment 2012 : Implement Toyota Production System (TPS) in TPR 2013 : Selected as Bosch Preferred Supplier 2013 : LRP Best Practice from GIZ 2014 : Additional SMT line : Introduced Soldering Robot : In-house Parylene Coating : Green Industry Award Level3 : BAT Best Performance from GIZ 1990-1995 1996-2000 2001-2005 2006-2010 2011 2014 2001 : Listed in Thailand Stock Exchange as 3rd company in MAI : Integrated ERP, AOI & BGA Xray 2002 : Major Expansion & Became Lead Free : Web Base Material Planning : Sony 5ppm award 2003 : Certified TS16949, ISO 14001 : Merged TT&TP 2004 : Listed in SET (Stock Exchange of Thailand) : TPR 6K Sqm. Expansion : Clean room class 100K & Flip Chip Implementation : Bar Code Implementation 2006 : Pioneer Best supplier : Start Corporate Improvement Team : Denmark office 2007 : Forbe Asia Best Under 1B$ Award Deloitte Technology Fast 500 Asia Pacific : Pioneer Best supplier 2008 : TPP 10K Sqm. Expansion : IPO office in Singapore : Certified ISO13485 2009 : Certified ISO18001 : Thailand Lean Award : Lean Best Practice Award : Zero Accident Award : Excellence Safety, Health & Environment in Workplace 2010 : Zero Accident Award Highlight Awards Certification
Headcounts 1,33 headcounts 0 Management 50 Engineer 67 Admin staff/supervisor 272 Technician 72 Operator/other 869
Best Practice Award
Major Customers and International Certification Prachinburi Factory Key Customers & Products Applicants Established since 1996 Certificated of International Standard
Team Factory Rangsit Factory Prachinburi Factory ESCO Projects Established since 1990 Established since 1996 23,200 Sq. M Total area under the building
Team Rungsit Factory
Team Prachinburi Factory
Utility System Water-Cooled chillers (350 tons x 2 units) Cooling tower (450 tons x 3 units) Chilled Water Pumps (45kW x 2 units) Air handling unit (AHU x 11 units) Air compressor plants (3units) Condenser Water Pumps (22kW x 2 units)
Energy Expense Trend 2012-2014 How to reduce Energy Expense? Sep 12 Line -9 Start Production Nov 13 Line -3 Start Production Mar 14 Line -24 Start Production May 14 Line AV1 Start Production ❷ ❶ ❸ ❹ Others (Plug), 5.0% Air Compressor, 10.0% Lighting, 17.0% Air Condition, 3.0% Chiller System, 20.0% Production M/C, 45.0%
3. Team Energy Saving Approach EPC Contract by Facilitation Approach Guaranteed Saving Model Shared Saving Model Guaranteed Rebate (CHAUFFAGE)
3. Team Energy Saving Approach EPC Contract by Facilitation Approach
4. ESCO Projects Organization Chart Mr. Kamol BMC Facilitators Mr. Rungrit L. Chairman Mr. Monthon GIZ Projects manager Mr. Passakorn M. Leader Mr. Manoch P. Main Coordinator Mr. Pisit H. Energy Com. Leader Mr. Pisit H. Sub-Coordinator Facility Group Production Group Engineering Group Finance Group Mr. Samrit S. Facility Ms. Uraiwan R. PCBA Production Mr. Jessada Engineering Ms. Rattana Account / Finance Issued By Checked By Approved By Mr,Manoch P.. Mr.Passakorn M. Mr.Rungrit L. Effective Date : 01-June-2015
5. ESCO Projects Timeline by Facilitation Approach ESCO Projects Timeline at TPP Plant Progress Follow up : Next Meeting 17-Nov-2015 Advisories Meeting : Next Meeting -Nov-2015 ESCO Bidding Review Bidding & EPC Documents
6.1 Projects Follow up Working Team set periodical meeting by GIZ / BMC / TP Projects Progress explanation to TP s Management member by GIZ / BMC / TP
6.2 Preliminary Energy Audit Measurement installation on Utility System By BMC Measurement installation on Process Machine By BMC
7.1 Energy Breakdown of Chilled Water System Energy Consumption and Loading Condition
7.2 Energy Breakdown of Air Handling Unit Zone A PCBA Temperature & Humidity
7.3 Energy Breakdown of Process Machine Item Process Machine Energy Consumption Ratio (kwh/yr.) (%) 1 Wave Soldaring M/C 221,566.50 17.06 2 Reflow M/C 475,855.20 36.64 3 AQM Washing M/C 51,096.24 3.93 4 SMT M/C 769,639.50 59.25 Total 1,518,157.44 100.00
Before Estimation TEAM Comparison of Process Machine
ECMs 8. 1 Energy Conservation Measures For Saving Projects Energy ECM For Utilities Cost & % Saving Saving Saving by ECM (kwh/yr) Process Machine (Baht/yr) 1) VSD/High efficiency chiller 1.1 VSD Chiller (at varied load) 41.42% 257,849.64 1,044,291.0 1.2 VSD Chiller (at load 80%) 32.53% 309,859.00 1,254,928.9 1.3 High Efficiency Chiller (at load 80%) 30.12% 281,366.00 1,139,532.3 2) VSD Air compressor 32.26% 89,626.39 362,986.8 3) Replace High efficiency Machine 3.1 PCB Cleaning Machine (TRIDEN PCB Washing M/C 38.32% 79,140.04 320,517.1 ZOD DUO) Wave Soldering M/C 3.2 Wave Soldering Machine (WD 350R) 47.52% 68,688.00 278,186.4 3.3 Reflow Machine (PYRAMX 150.12A) 70.74% 144,160.00 583,848.0 4) High Efficiency Motors 2.72% 13,593.45 55,053.4 5) Solar Light Tube 90.00% 8,299.80 33,614.1 6) Reduce infiltration/exfiltration (Air 24.54% 1,948.51 7,891.4 curtain) 7) High efficiency nozzle 18.81% 2,804.11 Pressure 1 Kg/ 11,356.6 cm2 8) Reduce air leakage in the pipeline 11.00% 27,844.08 112,768.5 9) Reducing setting pressure of air compressor (1 bar) Chiller System Ozone Water System Air Compressor Reflow Oven M/C Reduction Leakage Reduce Setting Air Solar Light Tube High Eff. Motors 8.00% 23,855.08 96,613.0 Total (1) 16.14% 717,809.10 2,907,126.8 Note (1) : ECM 1.1 VSD Chiller (varied load) Total (2) 17.31% 769,818.46 3,117,764.7 Note (2) : ECM 1.2 VSD Chiller (at load 80%) Total 9 items Approach
8.2 Energy Conservation Measures for ESCO ECMs % Saving by ECM ECM For Utilities & Process Machine Energy Cost In Saving (kwh/yr) Saving (Baht/yr) 1) VSD/High efficiency chiller 1.1 VSD Chiller (at varied load) 41.42% 257,849.64 1,044,291.04 1.2 VSD Chiller (at load 80%) 32.53% 309,859.00 1,254,928.95 1.3 High Efficiency Chiller (at load 80%) 30.12% 281,366.00 Air Compressor 1,139,532.30 2) VSD Air compressor 32.26% 89,626.39 362,986.88 3) Replace High efficiency Machine 3.1 PCB Cleaning Machine (TRIDEN ZOD DUO) Chiller System Ozone Water System PCB Washing M/C Wave Soldering M/C Reflow Oven M/C 38.32% 79,140.04 320,517.16 3.2 Wave Soldering Machine (WD 350R) 47.52% 68,688.00 278,186.40 3.3 Reflow Machine (PYRAMX 150.12A) 70.74% 144,160.00 583,848.00 Total (1) 14.38% 639,464.07 2,589,829.48 1 Note (1) : ECM 1.1 VSD Chiller (varied load) Total (2) 15.55% 691,473.43 2,800,467.39 1 Note (2) : ECM 1.2 VSD Chiller (at load 80%) Total 5 items Approach Total (3) 14.91% 662,980.43 2,685,070.74 1 Note (3) : ECM 1.3 High Efficiency Chiller (at load 80%)
8.3 ESCO Factory Visit On 30-Oct-2015, ESCO 4 companies visited at Team Prachinburi Plant. -Team Overviews - Energy Background Information - Bidding Process Explanation [ Team Factory Tour ] - Utility System Explanation - Key Process Machine Explanation
9. Energy Performance Contract Process GIZ & Team BMC Facilitators Projects Progress : We are now proceeding to ESCO Bidding Process step-2
10. Benefit of Facilitation Approach Facilitators support Team, enabling the energy saving project development Facilitators foster competition among ESCOs Facilitators create a fair and level playing field for competition ESCOs could benefit from increased market potential with active Facilitators More energy saving measures at lower prices ( competition between ESCOs ) More confidence in project success and lower financial cost