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  • GoodyearIntegrating Continuous

    Improvement in Energy/GHG

    Aiman Abdrabou, CEM, CSSBBGlobal Manager Energy & GHG

    Goodyear Global EHS Sustainability

    1Goodyear - A Sustainability Journey

  • Biography

    - Aiman Abdrabou

    Over 15 years in the field of Energy Engineering / Management

    AEE International Award 2014 Energy Manager of the Year

    Working with Goodyear since 2009 as a Global Manager Energy & GHG

    Prior to Goodyear, worked with DTE Energy and General Motors

    Responsible for developing and implementing energy and greenhouse gases (GHG)

    strategies for 52 Goodyear manufacturing facilities around the world

    Conducted more than 500 energy assessments/audits (industrial and commercial)

    Degrees:

    B.S. Aerospace Engineering,

    M.S. Industrial Engineering

    Masters Engineering Management

    Certifications:

    Certified Six Sigma Black Belt (CSSBB) - American Society for Quality

    Certified Energy Manager (CEM) - Association of Energy Engineers

    Certified Energy Auditor (CEA) - Association of Energy Engineers

    Carbon Reduction Manager (CRM) - Association of Energy Engineers

    Certified Demand Side Management (CDSM) - Association of Energy Engineers

    Goodyear - A Sustainability Journey 2

  • Why is Sustainability Important at Goodyear?

    Global increase in visibility and emphasis on environmental issues

    Consumers expect leading companies to be environmentally responsible

    Sustainability conveys long-term environmental and social impacts, and financial longevity

    Goodyear can better capitalize on its industry-leading environmental record

    Goodyear - A Sustainability Journey 3

  • Tire Consumers Expectations

    Todays consumers have high expectations of tire companies:

    Produce tires for nearly every type of personal or commercial

    vehicle

    High-quality products with many fuel-efficiency and

    performance options

    Cost of products are affordable

    Produce these products while being responsive to global

    environmental concerns

    Goodyear - A Sustainability Journey 4

  • Tire Industry Issues

    Highly dependent on fossil fuels Tire Materials

    Fuels for Transportation

    Concern about the continued availability and cost of fossil fuels as the world

    demand increases

    An estimated 4% of the global oil consumption is used to overcome tire

    rolling resistance during vehicle use

    Goodyear - A Sustainability Journey 5

    External Footprint

    Tire Use

    87%

    Internal

    Footprint

    13%

    Tire Mfg

    22%

    Raw

    Materials

    74%

    Raw Material

    Transport 3%

    Product

    Transport 1%

    Tire use (rolling resistance) is the most significant tire footprint contribution

    Total Tire Life CO2 Emissions

  • Integrating Continuous

    Improvement in Energy/GHG

    DMAIC Methodology

    Goodyear - A Sustainability Journey 6

  • Based on Jack Simpson Systems Alive 2000

    Requirement

    Champion/Leader

    System Resources (Teams)

    System Design/ Process Documentation

    Certification/Training

    Commitment

    Corrective Action / Plan

    Accountability/Consequences

    Feedback

    Global Energy System Components

    Goodyear - A Sustainability Journey 7

  • Integrating Continuous Improvement in Energy/GHG

    Six Sigma DMAIC Methodology Overview

    Goodyear - A Sustainability Journey 8

    Objective and Goals Energy/GHG Intensity Reduction Indicators

    Energy /GHG Savings Indicators

    Define (D): Identify Energy/GHG Opportunities Plant Energy Coordinator and BC Energy Champions will identifyfeasible energy initiatives to achieve the plants energy goal.

    Energy champions will work with their energy teams to develop the detailed description and perform the data collection of the identified initiatives.

    Measure (M): Quantify Energy/GHG SavingsPlant Energy Coordinator and BC Energy Champions will use the collected data to perform saving calculations of the energy/GHG opportunities.

    Opportunities should be prioritized based on Simple Payback (SPB) and/or ROI.

    The energy projects cost, duration, owners should be determined in this phase.

    Analyze (A): Develop Action Plan BC Energy Champions will develop a plan to execute the selected energy/GHG opportunities for the current year.

    Action plans should include project description, owner(s), due date, savings, cost and SPB/ROI

    Improve (I): Implement Action PlanPlant Energy Coordinator and BC Energy Champions to implement the approved action plan.

    Implementation status of energy initiatives will be documented and reported on a monthly basis to the plants (EPM) and to region using CI Tracker.

    Control (C): Monitor Energy programEnergy Performance Metric (EPM) Board will be used to track each BCs energy performance and get the plant leadership support.

    RSEnergyMetrix Monitoring System to be used to track the plants energy performance using energy charts and trends.

    Plants will update monthly actual energy savings in CI tracker and add the new energy initiatives.

    Report progress during NAT Monthly Conf Call/WebEx

    Energy Scorecard submitted monthly to the region

  • Global and Regional Energy/GHG

    - Support Structure

    Global Manager works with Regional Energy Manager on energy / GHG programs

    Goodyear has a Regional Energy/GHG Manager for each region (SBU)

    Plants are supported by the Regional Energy Manager to achieve the indicators

    Each plant receives multiple energy plant visits every year to drive the strategy

    These visits are intended to help in the following:

    Drive the strategy in the plants to achieve the indicator and CI saving goals

    Share common energy best practices among plants

    Provide technical assistance to the plant energy teams

    Work with the BC energy champions on executing the BC energy action items

    Help the plant to seek opportunities to secure government, state and utility

    energy grants and rebates

    Goodyear - A Sustainability Journey 9

  • Plant Energy Coordinators/Manager:

    Roles and Responsibilities

    Expectations from Certified Energy Managers:

    Own the energy initiatives in the plant is a primary role

    Identifying and calculating energy savings is important to help prioritize

    and select the appropriate energy initiatives

    Lead the BC energy champions and execute energy initiatives

    Provide technical assistance to the energy champions that are not CEMs

    Follow up with the energy champions in each business center

    Run progress meeting with the energy champions in each department

    Run a monthly meeting at the energy board (EPM) with plant leadership

    and the energy team to discuss progress and align priorities

    Goodyear - A Sustainability Journey 10

  • Certified Energy Manager (CEM):

    AEE in-house training program

    Goodyear - A Sustainability Journey 11

    Goodyear has approximately 30 associates that are recognized

    as a Certified Energy Managers (CEMs) accredited by the

    Association of Energy Engineers (AEE)

    Goodyear conducted many AEE in-house training sessions to

    certify the plant energy manager to become CEM

    North America (NA) & Latin America (LA) teams conducted in

    Cleveland in 2010 (22 associates)

    Asia Pacific (AP) region conducted in China in 2012 (11 associates)

    NA & LA teams conducted in Cleveland in 2013 (6 associates)

    Global conducted in Goodyear HQ in Akron, OH in 2014 (3

    associates)

  • Developed Global Lighting Standards:

    Training for Indoor Lighting Design

    Lighting Level: Comply with the global lighting

    standards lighting level in each area

    Lighting Technology: Select the lighting technology

    that achieves a power density of 0.8-1.0 Watt/SQFT

    Lighting Scoring (Twice a year):

    Energy Dashboard and Scoring is detailed in the NA

    lighting specifications

    Team training was conducted to certify each energy

    coordinator in lighting design

    Goodyear - A Sustainability Journey 12

  • Goodyear - A Sustainability Journey 13

    Best of the Best - Americana Energy Team

    - Energy Conservation Internal Committee (CICE)

    Operational Team :Machine operators, Mechanics, Electricians, Power House Operators, Quality Monitor,

    Safety Technician, Chemical Technician

    Support Team : Manager, Auditor, Power House Supervisor, Maintenance Supervisor

    Coordenador CICEMAIA

    Coordenadora Meio AmbienteIS0-50001

    RENATA

    FacilitadorGUSTAVO

    FacilitadorOSIEL

    TNC ETECH PRODUO

    ENT BARBAN SILVA

    CAL LINCON RODRIGUES

    BBS SIA TARDIO

    DIVISO - A

    TNC ETECH PRODUO

    CON DAMIO DARIO

    VUL CASTANHARO MEDEIROS

    FIN CASTANHARO MIGUEL

    DIVISO - B1

    TNC ETECH PRODUO

    COM OSTI ANDR

    VUL CELSO PIGATTO

    OTR MEFFE DIAS

    PREP MEFFE OSTI

    DIVISO - B2 / P3

    TNC ETECH

    FACILIDADES

    FAC NADAI

    TNC ETECH

    UTILIDADES

    UTIL ALVES

    TNC

    ENT

    CAL

    BB

    RICARDO

    ALYSSON

    GEISUN

    REPRESENTANTES CICE

    DIVISO - A

    TNC

    CONS ANA

    REPRESENTANTES CICE

    DIVISO - B1

    VULC PEDRO

    TNC

    VULC

    CONS

    PREP

    P3

    MICHEL

    ZANAGA

    MACIEL

    REPRESENTANTES CICE

    DIVISO - B2 / P3

    NILSON

    TNC

    STOCO

    REPRESENTANTES CICE

    FACILIDADES

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