REDUCING ELECTRICAL CONSUMPTION IN THE FOREST PRODUCTS INDUSTRY USING LEAN THINKING
Dr. Henry Quesada-Pineda
Department of Sustainable Biomaterials
Shawn Crawford M.F. Student
Department of Sustainable Biomaterials
Dr. Earl Kline Department of
Sustainable Biomaterials
PTF BPI 11/06/12 King and Prince Beach & Golf Resort St. Simons Island, GA
Overview
Background
Problem
Purpose and Objective
Methods
Results
Conclusions
Background
Energy in the Forest Products Industry
Industrial 26% U.S. electrical 14% Forest Products
Industry < 1% Large majority of the
industry generates onsite energy
Background
Process Improvements Total Productive Maintenance (ideology) Continuous Improvement (ideology) Six Sigma (tool) Lean (ideology) Service Performance Improve quality and reduce cost Minimize the use of assets Track performance improvements Decrease waste
Background
Why Lean?
Lean is customer oriented
Lean thinking is reducing waste by focusing on value-added processes
Value is defined by the customer
“Lean thinking is basically doing more with less." – James Womack
Lean and Energy Toolkit
Energy Treasure Hunts
Value and Energy Value Stream Mapping
Energy Kaizen Events (EPA, 2007)
Background
Process Mapping Business Process Re-engineering Work Flow/Spaghetti Diagram Flow Chart Value Stream Mapping
Background
Problem
Sector Opportunity for Improving Energy Efficiency Cleaner
Fuels Combined Heat and Power
Equipment Retrofit/Replacement
Process Improvement
Research and Development
Cement Medium Low High High Medium Forest Products Medium Low Medium High High
Integrated Steelmaking
Low Medium Low Medium High
Metal Casting Low Low Medium Medium Medium
Metal Finishing Low Medium Medium High Medium
Petroleum Refining
Low High Medium Medium Medium
(EPA, 2007)
Purpose and Objectives
Purpose: Estimate the impact “lean thinking” has on electrical
consumption Objectives 1. Install Energy Management System 2. Identify Product/Value Chain 3. Map Current Process and Energy Consumption
Using Value Stream Mapping (VSM) 4. Create Future State Value Stream Mapping (VSM)
Methods • Energy Management System (EMS) • Installation done by EnerNOC • Test EnerNOC system Install EMS
• Evaluate historical data • Highest volume product Identify
Product/Value Chain
• Flow chart high volume product process steps • Current state VSM of high volume product • Incorporate electrical consumption Current State VSM
• Develop auditing tool • Come up with two-three electrical energy saving
recommendations • VSM implementing electrical savings recommendations
Future State VSM
Results: Install EMS
Provides real time electrical feedback
Rate of 5 minute intervals
Manage energy daily instead of monthly
Results: Install EMS
(Enernoc, 2011)
Results: Identify Value Chain
Results: Identify Value Chain
Results: VSM and Electrical Consumption
Results: VSM and Electrical Consumption
Direct Estimation= power rating (PR) for process
Amps X Volts= PR in kWh
Results: VSM and Electrical Consumption
Cost allocation technique for electricity Driver is area in units of square feet
1 3 2 4 50 ft
100 ft
5 ft
5 ft
Example: Indirect Consumption
Results: VSM and Electrical Consumption
Results: VSM and Electrical Consumption
0
200
400
600
800
1000
1200
7/26/2011 9/14/2011 11/3/2011 12/23/2011 2/11/2012 4/1/2012 5/21/2012 7/10/2012 8/29/2012 10/18/2012
kWh
Day
Year Electrical Consumption
Thursday
Friday
Saturday
Sunday
Monday
Tuesday
Wednesday
Results: VSM and Electrical Consumption
Before: Fan A and B= 219.7kW Fan A= 93.2kW Lock Valve= 1.5kW Cleaning Pump= 5.8kW Total= 100.5kW
Fan B= 111.9kW Lock Valve= 1.5kW Cleaning Pump= 5.8kW Total= 119.2kW
Results: VSM and Electrical Consumption
y = -1.5042x + 978.62 R² = 0.0217 0
200
400
600
800
1000
1200
0 20 40 60
kWh
Sample Per Day
Thursday
Electrical Consumption Per Day
Linear (Electrical Consumption Per Day)
y = -1.0009x + 917.63 R² = 0.0077 0
200
400
600
800
1000
1200
0 20 40 60
kWh
Sample Per Day
Tuesday
Electrical Consumption Per Day
Linear (Electrical Consumption Per Day)
Results: VSM and Electrical Consumption
R² = 2E-05
R² = 0.0153
0.00
5.00
10.00
15.00
20.00
25.00
30.00
35.00
40.00
11/3/2011 0:00 12/23/2011 0:00 2/11/2012 0:00 4/1/2012 0:00 5/21/2012 0:00 7/10/2012 0:00 8/29/2012 0:00 10/18/2012 0:00
SqFt
/kW
h
Day
Weekly Production Average Per Daily Electrical Constumption
Monday
Tuesday
Wednesday
Thursday
Friday
Linear (Tuesday)
Linear (Friday)
Results: VSM and Electrical Consumption
R² = 0.0011
0
2000
4000
6000
8000
10000
12000
14000
16000
11/3/2011 12/23/2011 2/11/2012 4/1/2012 5/21/2012 7/10/2012 8/29/2012 10/18/2012
Sq. F
t.
Day
Jan.-Sep. Production Rates
Jan.-Sep. Production Rates
Linear ( Jan.-Sep. Production Rates)
Results: VSM and Electrical Consumption
1 sec
0.06 days
1.1 sec
1.45 days
2.6 sec
0.07 days
3 sec
0.12 days
Production Control
Weekly Forcast
Veneer Suppliers2 shipments per week
8,807 Panels 1
Head Clippers
T/T= 3.7 sec
C/T= 1.1 sec
C/O= N/A
Time Available= 27000 sec
Travel Time=1.55
Power Rating= 10kW
347Panels 1
Guillotine
T/T=1.4 sec
C/T= 2.6 sec
C/O=N/A
Time Available= 27000 sec
Travel Time=0.53 sec
Power Rating= 7.6 kW
347Panels
1
Whole Challenge Guillotine
T/T=1.1 sec
C/T=1 sec
C/O=N/A
TA=27000 sec
Travel Time=2.2 sec
Power Rating=2kW
756Panels
2
Inspectors
T/T=1.2 sec
C/T=0.8 sec
C/O=N/A
TA=27000
Travel Time= 1 sec
Power Rating=3kW
2,520Veneer Carts
Panels
Core Suppliers3 trucks per week
48 Raw Core
168Panels
Buffer Stock
1
Holzma
T/T=4.8 sec
C/T=1.3 sec
C/O=N/A
TA=27,000 sec
Travel Time=45 sec
Power Rating=20.4kW
1,427Panels
1
North Tech
T/T=5.5 sec
C/T=5 sec
C/O=20 sec
TA=27,000 sec
Travel Time=46 sec
Power Rating=3.9kW
2
Glue Spreader
T/T=3.6 sec
C/T=1.6 sec
C/O=N/A
TA=16,200 sec
Power Rating=1.2kW
240panels
1
Flat Panel Press
T/T=3.6 sec
C/T=1.9 sec
OEE=75.9%
TA=16,200 sec
Travel Time=1.58sec
Power Rating= 44.2kW
275panels
1
Shipping
T/T=2.7 sec
C/T=1.4 sec
C/O=N/A
TA=1,800 sec
Travel Time= 137 sec
Power Rating=0.715kW
491 staging panels
Shipments to Plant 12
Atkins Door Plant
4 shipments/day1,816 panels/day
Daily Automated ScheduleDaily Schedule
540stagingpanels
11.58 hours O.57 hours 0.46 hours 0.99 hours
1.3 sec
0.04 days
5 sec
0.31 days
1.6 sec
O.53 days
1.2 sec
0.05 days
1.4 sec
0.06 days
Processing Time= 18.2 seconds
Production Lead Time= 22.35 hours
0.11 days
4.24 hours 0.42 hours 0.48 hours 0.85 hours
0.29 hours 2.47 hours
Results: VSM and Electrical Consumption
2,520Veneer Carts
Panels
2
Glue Spreader
T/T=3.6 sec
C/T=1.6 sec
C/O=N/A
TA=16,200 sec
Power Rating=1.2kW
240panels
1
Flat Panel Press
T/T=3.6 sec
C/T=1.9 sec
OEE=75.9%
TA=16,200 sec
Travel Time=1.58sec
Power Rating= 44.2kW
275panels
1
Shipping
T/T=2.7 sec
C/T=1.4 sec
C/O=N/A
TA=1,800 sec
Travel Time= 137 sec
Power Rating=0.715kW540
stagingpanels
1.6 sec
O.53 days
1.2 sec
0.05 days
1.4 sec
0.06 days
4.24 hours 0.42 hours 0.48 hours
Processing Time= 18.2 seconds
Production Lead Time= 22.35 hours Total Direct Consumption= 541.26kWh/day
Total Indirect Consumption= 17.32 kWh/day
Results: VSM and Electrical Consumption
Select SIC code
Instructions: Input your plant area (ft2) 50,000 1. Only fill up the black cells. Do not modify or change any of the formulas Input the number of employees 1232. Select your industry classification (SIC code)3. Indicate your facility size in terms of square footage and number of employees.
Factor ARC code
Item description
Level of compliance
Cost of no compliance (based
on ft2)
Cost of no compliance (based on
employees)
Average payback (years)
Number of implementation
2.1133 ADJUST BURNERS FOR EFFICIENT OPERATION 4 $1,779 $9,852 0.41 8
2.1135 REPAIR FURNACES AND OVEN DOORS SO THAT THEY SEAL EFFICIENTLY 1 $0 $0 0.00 0
2.1231 ESTABLISH BURNER MAINTENANCE SCHEDULE FOR BOILERS 4 $1,252 $7,292 0.79 9
2.1232 KEEP BOILER TUBES CLEAN 4 $19,283 $21,410 0.58 12
2.1233 ANALYZE FLUE GAS FOR PROPER AIR/FUEL RATIO 4 $3,517 $4,420 0.68 84
2.2113 REPAIR OR REPLACE STEAM TRAPS 3 $16,163 $4,111 0.56 8
2.2122 INSTALL / REPAIR INSULATION ON CONDENSATE LINES 4 $28 $321 1.16 12
2.2123 INSULATE FEEDWATER TANK 4 $292 $397 1.04 14
2.2131 INSULATE STEAM / HOT WATER LINES 2 $1,001 $2,763 1.15 76
2.2133 REPAIR LEAKS IN LINES AND VALVES 5 $0 $0
2.2135 REPAIR AND ELIMINATE STEAM LEAKS 1 $11,502 $39,676 1.53 20
2.2153 CLOSE OFF UNNEEDED STEAM LINES 4 $344 $610 0.01 2
Heat containment2.2523
REDUCE INFILTRATION TO REFRIGERATED AREAS; ISOLATE HOT EQUIPMENT FROM REFRIGERATED AREAS 4 $344 $610 0.01 2
2.4111 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS 2 $1,157 $2,277 1.07 340
2.4133 USE MOST EFFICIENT TYPE OF ELECTRIC MOTORS 3 $1,152 $1,780 3.35 337
2.4151 DEVELOP A REPAIR/REPLACE POLICY 4 $653 $1,491 0.88 26
2.4157 ESTABLISH A PREDICTIVE MAINTENANCE PROGRAM 1 $2,606 $3,382 0.19 10
4. Rate every opportunity using the following scale: 5 (No corrective action required), 4 (Evaluation for potential improvement required), 3 (Corrective action required), 2 (Urgent corrective action required), 1 (Inmediate corrective action required). and 0 (Emergency situation)
Furnaces, ovens, and directly fired operations
Boilers
Steam
Motors
Industrial Assessment Center Database (IACD)
Future State VSM
Kaizen event: Incorporate energy audit tool 2-3 energy saving recommendations Implement recommendations Create future state VSM incorporating energy
saving recommendations Evaluate impact through energy management
system (EMS)
Conclusion
Identification of best lean practices to save electrical consumption in a wood products manufacturing environment
Development of an auditing tool based on lean principles to identify energy saving opportunities
For this specific case study, implementing “lean thinking” reduces monthly electrical consumption by X amount of kWh
A developed way of incorporating electrical consumption into a VSM
References
Slide 3: U.S. Energy Information Administration (EIA). Annual Energy Outlook 2011. 2011. Available at <http://www.eia.gov/forecasts/aeo/MT_electric.cfm>. Last Accessed Sep. 26, 2011 Slide5: Womack, J. P. and D. T. Jones. 2003. Lean Thinking: Banish Waste and Create Wealth In Your Corporation. Second edition. Simon & Schusters. New York. Last Accessed Feb. 17, 2012 Slide 5: United States. Environmental Protection Agency. Lean and Energy Toolkit. Washington D.C.: Ross & Associates Environmental Consulting, Ltd., 2007. Last Accessed Feb. 17, 2012 Slide: 7: United States. Environmental Protection Agency. Energy Trends in Selected Manufacturing Sectors: Opportunities and Challenges for Environmentally Preferable Energy Outcomes. Fairfax: ICF International, 2007. Last Accessed Feb. 17, 2012 Slide 11: EnerNOC:Demand Smart. Graphic. EnerNOC, Boston, MA. 2011. Available at <www.enernoc.com>. Last accessed Feb. 7, 2012
Thank You Questions? E-mail: [email protected] Project funded by the Wood Education Research Center (WERC) at the US Department of Agriculture