Linking Energy Efficiency & Lean Manufacturing

Presentation to

March 30, 2010

Richard F. Rappa, PE, CEM Vice President

UPSTATE ENERGY EXPO 2010

Linking Energy Efficiency to LEAN

Linking Energy Efficiency to LEAN

LEAN manufacturing produce just-in-time products using right sized equipment

and limited product movement

Inefficient energy use overproduction, un-optimized product flow, over-sized equipment, and carrying inventory

Just-in-time production less floor space, less energy to heat, cool, and light the

facility

Linking Energy Efficiency to LEAN

Wasteful Energy Use – Manufacturing Losses that lead to inefficient energy use Reduced speed Defects and rework Yield losses Setups and adjustments Idling Breakdowns

Linking Energy Efficiency to LEAN

Total Productive Maintenance optimizes the effectiveness of manufacturing equipment

Integrating best practices for effective energy management will maintain effectiveness

Right-sized Equipment will optimize energy efficiency per unit of production

Improving product flow will reduce energy required to support production processes

Standard work practices is the end result of a reliable and optimal process

Linking Energy Efficiency to LEAN• Energy Stream Mapping - Integrate

energy into the value stream map

Process

INPUTS

OUTPUTS

Raw

Materials

Time

Labor

Water

Energy

Air Emissions

Waste (Haz/Non-haz)

Wastewater

Final Product

Linking Energy Efficiency to LEAN• Energy stream mapping - Integrate energy into

the value stream map• Identify, quantify, & estimate energy use at each

point along the map – follow the material line

Process 1 Process 2 Process 3

Energy Used

Energy Needed

• Energy stream mapping - Integrate energy into the value stream map

• Identify, quantify, & estimate energy use at each point along the map – follow the material line

• Discuss energy use at each point & develop opportunities Use vs. need analysis Waste Recovery opportunities Alternate technology

• Develop a future state energy map

Linking Energy Efficiency to LEAN

Case Study Examples

Paper Manufacturer• Specialty paper products , 350,000 sf

manufacturing plant, 115 employees, 24 X 7 operation

Paper Machine

Current StatePulp, etc33 million kWh3.6 million gallons fuel oil

58,000 tons

Effic: 11.3 MMBTU/ton; 504 tons/person

Future State

Projects• Deckle board upgrade - 4% yield • Dryer hood economizer upgrade - 5% productivity

Paper MachinePulp, etc33 million kWh3.6 million gallons fuel oil

63,000 tons

Incentive: 50% of Project Cost!2.8 mill kWh saved0.3 mill gals fuel saved

Effic: 10.4 MMBTU/ton; 548 tons/person

(4) Bottling Lines

Current State

58 million gallons

Effic: 946 BTU/gal

Future State

Projects• Simultaneous process heating & cooling • Open geothermal loop w/heat recovery chiller

(4) Bottling LinesWater, etc1.3 million kWh350,000 therms

58 million gallons

Incentive: $130,0001.1 mill kWh saved117,000 therms saved

Effic: 680 BTU/gal

Beverage Manufacturer• Beverage products , 284000 sf

manufacturing plant, 350 employees, 24 X 7 operation

Water, etc.2.4 million kWh467,000 therms

Manufacturing

Current State

Finished Goods

Effic: 216 MBTU/SF

Future State

Projects• Product flow improvements, plant consolidation• Right sizing/enhancing process utilities• Lighting, HVAC, Envelope improvements

ManufacturingRubber, Plastic, etc.2.7 million kWh75,000 gal fuel oil107,000 SF cond space

Finished Goods

Incentive: $363,0003.4 mill kWh saved132,000 gal fuel saved55% reduction in space

Effic: 191 mmBTU/SF

Rubber & Plastics Engineering Products Manufacturer• Specialty products , 162 employees,

24 X 5 operation

Rubber, Plastic, etc.6.1 million kWh207,000 gal fuel oil240,000 SF cond space

Questions