2015 trifecta 1 - excellence in manufacturing consortium...2016 –energy management national award...

Andrew Hejnar MSc EnMS, P.Eng, CEM, CPEnMS, SEP PV, CRM, CEA, 3M Canada Energy Manager

ENERGYMANAGEMENT

2. All Rights Reserved.31 May 2018© 3M 3M Confidential.

Since 1902

● Subsidiaries in 71 economies

● Sales in nearly

200 economies

● ~90,000 employees

● International sales $18B

● 200+ factories

● Sales: $30.3B

● Free Cash Flow: $5B

● R&D investment: $1.8B

● 55,000+ products

● +100,000 patents

2

2015 figures

3@ 2016 3M. All Rights Reserved.3M Confidential3M Confidential

Sales & Marketing

Manufacturing/Converting

Technical Capabilities

Driving Progress around the World

Mexico

Brazil

Colombia

Venezuela

Argentina

Chile

Costa Rica

El Salvador

Panama

Ecuador

Peru

Uruguay

Guatemala

Italy

France

UK

Turkey

Greece

Morocco

Canada

Jamaica

Dominican

Republic

Puerto Rico

Trinidad &

Tobago

Poland

Czech Republic

Germany

Lithuania

Latvia

Estonia

Hungary

Romania

Ukraine

Kazakhstan

Russia

Japan

China

Taiwan

Vietnam

Thailand

Singapore

Indonesia

Hong Kong

Korea

Philippines

India

Israel

Egypt

Pakistan

UAE

Kenya

Malaysia

Sri Lanka

South Africa

Belgium

Portugal

Spain

Netherlands

Austria

Switzerland

Finland

Sweden

Norway

New Zealand

Australia

Denmark

Operations in 70+ economies

40 economies with manufacturing

operations

36 economies with laboratories


• Wetordry™ Sandpaper

• Scotch® Masking Tape

• Scotch® Cello Tape

• Scotchlite™ Reflective Signage

• 3M™ Flat Fold Disposable

Respirator with Valve

• Scotch-Brite™ Sponge

• Micropore™ Medical Tape

• Command™ Adhesive Strips

• Post-it® Notes

• 3M™ Aluminum Conductor

Composite Reinforced (ACCR)

• Cubitron™ Abrasives

• 3M™ 360 Encompass™ System

• Scotch® Magnetic Tape

Science improvinglives for more thana century


3M Canada

First 3M subsidiary (1951)

Employs 1,900 people

Seven manufacturing facilities

• Abrasives

• Tapes

• Healthcare

• Scotch-Brite

First subsidiary to have full time energy manager


2015-2025 Sustainability Goals

Health & Safety Education & Development

Raw Materials Energy & Climate Water

3M

Sustainability

Enhance

Competitive

Position

Aligned

with 3M

Values

Global

Sustainability

Commitments

Reinforce

Our

Reputation

Mitigate

Increasing

Energy

Cost

Employee

Satisfaction

What Motivates Energy Management at

3M?

8

3M’s Energy Policy

Energy Policy

PeopleMetering&

TargetingTechnology

& Projects

Vehicle to achieve this is ISO 50001 & SEP

3 Pillars of Successful Energy

Management

I. What you can’t measure

you can’t control – make

energy visible

II. Sub-metering

III. Energy Map – identify

where energy is used and

how much it costs

VI. Provide real-time energy

information for operating

personnel

IV. Establish energy

baselines

V. Establish energy targets

normalized for product

types, outside weather

conditions and any other

related variables

VII. Provide energy

consumption reporting for

management for tracking

and budgeting

1st Pillar of EnMS: Metering & Targeting


Deploying Energy Monitoring for New Capex

Equipment

Utility Threshold Criteria

Chilled Water > 50 TONS

Compressed Air > 75 SCFM

Natural Gas / LP 400 MBtu / hr

Electrical 35 kW

Steam 900 lbs / hr

Sub-Metering-New CAPEX program


1st Pillar of EnMS: Metering & Targeting

Where does CHP

makes sense?

Stable and low

natural gas prices

High electricity cost

Steady electrical

base load

Steady heat sink for

heat recovery

Government/local

utility support

Why?

Mature technology

Significant energy

savings (60-90%)

Better illumination

and light quality

Longer life – less

maintenance cost

The most expensive

energy – 7 HP of

electricity used to

produce 1HP of

compressed air

Replace with

equipment not

requiring

compressed air (ex.

electric blowers,

mixers etc.)

Reduce air leaks –

most plants leak at

20-30%

2nd Pillar of EnMS: Technology

Combined Heat & Power (CHP)

LED LightingCompressed Air

OptimizationHVAC Heat Recovery

Conditioning of air is

very expensive - $5

per CFM per year

Air balance studies

to reduce exhaust

and makeup air

Re-commissioning

of existing

equipment

Evaporative Cooling

Production

equipment such as

dryers and boilers

Compressors

Chillers (condenser

water)

3rd Pillar of EnMS: People

Why?

They operate equipment that

consumes energy

They know the equipment

better.

Better employee retention and

satisfaction

Increased trust in management

How?

Energy Conservation Awareness

Campaigns

Energy Training

Employee Suggestion Program

Communication

Let them know they matter Energy Awareness Comics

ISO 50001 Energy Management System

Voluntary international standard framework to manage energy

Based on “Plan-Do-Check-Act” continuous improvement cycle

Leads to improved energy performance

Integrates energy efficiency into

management processes

Many core elements in common with ISO

9001 (quality) & ISO 14001 (environment)

standards

PLAN

DO

CHECK

ACT

Energy Management System

(EnMS)

ISO50001 - Energy Management System

(EnMS)

ISO 50001 Standard Manual & ProceduresEnergy Policy

Energy Review Energy BaselineEnergy Performance

Indicators

Energy Measurement

Plan

SYSTEM

DO & CHECK

PLAN

CHECK & ACT

Standardized

Operations &

Maintenance

Energy Enablers: - Communications

- Training

- Design & Procurement

Energy Performance

Improvement Projects

Energy Performance

Monitoring.

Active Energy Team

Internal AuditManagement Review External Audit

Energy Objectives,

Targets & Timelines

Energy Review Energy BaselineEnergy Performance

Indicators

Energy Action Plans Energy Training PlanEnergy Communication

Plan

Energy Measurement

Plan


Implementation Process

Building on existing 3M Energy Management legacy

Integrate a systematic Energy Management System into plant operations & culture

Leverage existing management system components, 3M business & operations systems where possible

Building

Integrate

Leverage



Certification

Re-Gap

Execution of the Work Plan

Work Plan Definition

Gap Assessment

Team understanding of the Standard

Establish Team

Senior management Commitment



EnMS Planning

• Energy Review

• EnPI’s

• Action Plans

EnMS Execution

• Training

• Monitoring

• Standardized O&M

• Energy Corrective & Preventative Actions

Management Review & Internal Audit

• Engage management team

• Close internal audit findings

Final Documentation

• Work the system and generate the records that demonstrate implementation


External Certification Process

• Review of EnMS documentation to determine readiness

Pre-Assessment

• Detailed investigation of all system elementsPhase I Audit

• On-site audit to examine evidence of implementation

Phase II Audit

• Energy performance improvement exceeding 15% over three years

Brockville Tape Achieved “Platinum” Level for SEP in

2011 and 2015


Location 3M ISO 50001/SEP Certifications – 24 sites worldwide

Canada SEP/ISO 50001 – 1st Canadian Enterprise with seven facilities certified (all sites SEP pending)

US SEP/ISO 50001 – Enterprise with seven facilities certified (all SEP)

Mexico ISO 50001 - one plant certification pending

Germany ISO 50001 - six plants certified

Poland ISO 50001 - two plant certified

Korea ISO 50001 - one plant certified

France ISO 50001 - one plant certified

Canada Brockville PSD , US Cottage Grove & Mexico SLP Site participated in pilot program for The Commission for Environmental Cooperation (CEC) as part of Clean Energy Ministerial in collaboration with Natural Resources Canada (NRCan), Mexico’s National Commission for the Efficient Use of Energy (CONUEE) and the US Department of Energy (DOE)


Enterprise-Level, North America

Canada Plants

Brockville 501

Brockville PSD

London Oxford

Montreal

Morden

Perth 301

Perth 302US

PlantsAberdeen

Cordova

Cottage Grove

Cynthiana

Decatur

Hutchinson

Prairie du Chien

North

America

Enterprise

Model

Mexico Plant

San Luis Potosi


Management responsibility (4.2)

• Energy Policy

• Leadership and commitment

• Organizational roles, responsibilities &

authorities

• Management Review (Site & Central Office)

(4.7)

• Communication

• Resources

Energy Sources

Energy Policy

(4.3)

Legal and other

Requirements

(4.4.2)

Improved

Energy

Performance

Energy Management System

• Context of the Organization and Interested

parties

• Scope of EnMS

• EnMS Processes

Support

• Competence, Training and Awareness (4.5.2)

• EMIS (development, operation and maintenance)

(4.6.1)

• Communication (4.5.3)

• Documentation & records (4.5.4, 4.6.5)

• Evaluation of compliance with requirements (4.6.2)

Energy Planning (

4.4)

Energy Monitoring,

Measurement,

Analysis (4.6.1) and

Corrective Action

(4.6.4)

Energy Team

and meeting

process

Improvement

• CAPA (4.6.4)

• Employee Suggestion System (ESS) (4.5.3)

• Internal Audit (4.6.3)

Enterprise Processes

Operational Control of SEUs

(4.5.5)

EnMS Support

Processes

EnMS

Management

Processes

Enterprise EnMS Process Map

Implement Energy Action

Plans (4.5.1)

Site Processes

Ensure consistent

Energy Planning

process

Central monitoring of

energy performance

using consistent criteria

and CAPA’s

Ensure consistent Energy Team

meeting and improvement action

process

Design & procurement

(4.5.6/4.5.7)


Benefits of Enterprise Model

Benefits Site - Level Enterprise – Level

Branding • Branding limited to site-level• Cannot be implemented to entire organization

• Branding applicable to entire organization• Increased visibility to customers

Commitment • Plant Manager • Senior-Executive Management & Plant Manager

Time/Effort

• Create & maintain separate manuals/procedures• Conduct external audit at each site• Document templates different for all facilities (ie. energy

planning)• Energy communication focused on smaller group of

suppliers• Energy awareness activity inconsistent from site-to-site• Creation & roll-out of energy training differs from site-to-

site

• Centralized system for common documents• Conduct external audits for sampled sites only• Standardized templates for all facilities• Energy communication focused on all suppliers• Energy awareness is consistent throughout all facilities• Creation & roll-out of common energy training

throughout organization



Benefits Site - Level Enterprise - Level

Cost• Higher cost for external audits• Higher implementation cost• Higher in-kind cost to maintain the EnMS

• Lower cost for external audits• Lower implementation cost• Lower in-kind cost to maintain the EnMS

Resources • Facility resources required for all aspects of EnMS

• Facility resources focus mainly on action plans & energy projects

• Central Energy Team streamlines general standard requirements

Ease of Implementation

• Higher duration due to starting from scratch • Lower duration due to existing foundation

Sharing Knowledge

• Limited knowledge sharing of best practices, non-conformities & failures between sites

• Less traction of energy efficiency guidelines for design & procurement

• Knowledge shared effectively amongst sites (reduced cost, time and resources)

• Common energy efficiency guidelines for design, procurement

• Life Cycle Analysis


Benefits of Energy Management System



Energy Efficiency Procurement Practice Energy Efficiency in Sourcing Standard


3 x Canadian Industry Program for Energy Conservation

(CIPEC) Awards

2014 – Corporate Stewardship

2016 – Energy Management National Award

2016 – Employee Awareness

Type Savings Equivalent Annual Usage

Electricity 126 GWh 10,500 households

Natural Gas 20 Mm3 7,400 households

CO2e emission 103,000 t 22,000 cars

Total Savings

$15 M

3M Canada Energy Management Achievements

Improved Energy Performance = Lower Cost

Increased Idea Generation Suggestion System

Improved O&M Practices

Increased Awareness of Energy Performance

Improved Procurement & Engineering Practices

Benefits of EnMS

3M’s Key Success Factors

Senior management commitment

Selection of team members

Expert consultant support

Government and local energy

suppliers’ support

Rigorous project tracking

Existing quality and environmental

management systems

Prior investments in energy management information system

Legacy of corporate leadership in sustainability

Questions?

2015 trifecta 1 - excellence in manufacturing consortium...2016 –energy management national award...

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