lean energy conservation program - uprmgreen.uprm.edu/pres/pres_lbosques.pdfrising awareness &...
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Lean Energy Conservation Program
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 § 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.
LPO’s Energy Policy
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.
Teamwork Makes the Difference!
LPO Lean Energy Methodology
Information
GatheringAssessment
LPO GovernanceLPO Governance
QRC QRC Quality MetricsQuality Metrics
BRC #1: S&OPBRC #1: S&OP1313--18 months18 months
TC : TC : Training Training CouncilCouncil
LPO Governance & Leadership Engagement
Structures…
Building
The Plan
Implementation
Monitoring
& FeedbackManagement
Directive
BRC #2: BRC #2: New ProductsNew Products
BRC #3: BRC #3: Business MetricsBusiness Metrics
BRC #4: BRC #4: ProjectsProjects���������������� � �� ������ ����� �� �������������������� �� ���� �������� �������
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Other tools used…
• Continuous Improvement Methodology (SIP)
– Lean
– Six Sigma
• Flowcharts
• Financial Analysis• Financial Analysis
• Usage Daily Monitoring
• SWOT Analysis
• ECT Monthly Meetings
Warehouse and Parking Lighting Retrofit
Warehouse Before Warehouse After
Savings: KWh Before: 1,158,422 KWh/yearKWh After: 621,813 KWh/year
Boiler Control System
Savings: Fuel Before: 1,274,000 Gal/yearFuel After: 1,231,000 Gal/year
KWh Before: 174,000 KWh/yearKWh After: 67,000 KWh/year
Solar Water Heaters Farm
Expected Savings: Yearly savings: 11,000 gal/year Aprox: $40,000 per year
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• 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
Two Years Results…
$0.141
$0.151
$0.158
$0.191
$0.120
$0.130
$0.140
$0.150
$0.160
$0.170
$0.180
$0.190
$0.200
$1.65
$1.97
$2.41
$3.46
$1.20
$1.50
$1.80
$2.10
$2.40
$2.70
$3.00
$3.30
$3.60
29,277,609
26,822,400
25,238,400
23,000,000
24,000,000
25,000,000
26,000,000
27,000,000
28,000,000
29,000,000
30,000,000
2005 2006 2007
KWh
$0.1202005 2006 2007 2008 Projected*
$/KWh
1,062,571
896,133853,039
600,000
700,000
800,000
900,000
1,000,000
1,100,000
1,200,000
2005 2006 2007
Gallons of Diesel Increase in Manufacturing Volumes
$1.202005 2006 2007 2008 Projected*
$/Gallons
Combined Savings
Electricity
$3,900,000
$4,100,000
$4,300,000
$4,500,000
$4,700,000
Fuel
$1,900,000
$2,100,000
$2,300,000
$2,500,000
$2,700,000
$3,500,000
$3,700,000
2005 2006 2007
Without any Improvement Actual
$1.0MM, 2yrs Savings
$1,500,000
$1,700,000
2005 2006 2007
Without any Improvement Actual
$834k, 2 yrs Savings
Some benefits are…
• Direct Benefits– Economic
– Environmental
• Indirect Benefits– Enhanced public image
Use of new technologies– 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
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
Rising awareness & Effective communications
• Energy Tips Brochure
• Energy Conservation Program Logo
• Monthly energy computer banners
• Awareness Stickers
¿Sabía usted que, el 13 de septiembre de 1991, e
l
Presidente de los Estados Unidos George Bush,
padre, proclamó a octubre como el mes de la
concientización sobre la ENERGIA?
¡Únete y empieza a ahorrar energía!
• Awareness posters
• Intranet News and Projects’ Presentations
• New employees/contractors orientation
• Logo affixed to Plant Uniforms
Change a Light… Change the World
• A Compact Fluorescent Lamp (CFL) give away as part of the Energy Star campaign
Pioneers within our Company
• Based on our policy and success, Global SPhas been using LPO as a benchmark and example for other sites
• Support deployment and implementation of the SPARC (SP Action for Resource 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
2007 Environmental Achievement Award for “Energy Excellence”
