process re-engineering for increased manufacturing efficiency
TRANSCRIPT
PRIMEProcess Re-Engineering for Increased
Manufacturing Efficiency
Connecticut Energy Efficiency Fund (CEEF)Commercial & Industrial Programs
December 21, 2010
Agenda About Daniel Penn Associates CEEF PRIME Overview
Program Objectives and Benefits Why Support Lean Manufacturing? Who Can Participate Program Procedures Proper Representation of Affiliation PRIME Events PRIME Incentives
Questions Adjourn
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About Daniel Penn Associates
30 Years; 300+ Projects
Diverse Commercial and Government Client Base
Certified Lean & Six Sigma Consultants
NU & UI PRIME Contract Supplier
D & B , GSA rating = Outstanding
Focused Approach to Address Client’s Needs
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D & B Rating Summary
Daniel Penn Rating
Performance Scale1 Outstanding2 Very Good3 Satisfactory4 Marginal5 Unsatisfactory
Overall Rating 1.33
Timeliness - Delivery Performance 1.20
Problem Responsiveness 1.50
Quality of Purchased Service 1.60
Total Cost 1.10
Technical 1.50
Attitude of Supplier Personnel 1.10
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LeanWise Complimentary Features
•Eliminatewaste and
reducecycle time
•The Goal: Maximize throughput
•Reduce variationand defects•Increase processpredictability
•Reduce downtimeand improve OEE
Connecticut Energy Efficiency Fund
Created in 1998 by CT State Legislature Programs administered by UI and CL&P
Provide technical assistance and cash incentives for business and residential energy efficiency projects
Money for programs comes from electric and natural gas utility customers and other funding sources
Conservation & Load Management Program Objectives Advance the efficient use of energy Reduce air pollution, carbon emissions
and negative environmental impacts Promote economic development and
energy security
PRIME Program Objectives
Provide businesses with an introduction to the benefits of Lean Manufacturing techniques by providing/funding, training and technical assistance
Reduce electric consumption per productthrough efficient manufacturing processes
Why CEEF Supports Lean Manufacturing
Lean manufacturing is a growth strategy:
Increased productivity + reduced operating costs + safer workplace = more profitable
business!
Lean Manufacturing and Energy Efficiency Producing more products in the same period of
time : 1) Saves on non-manufacturing electricity
consumption 2) Reduces losses in manufacturing equipment
consumption (i.e. less idle time) Note: also think of this as improving ratio of the
amount of energy used per product produced
The Benefits of PRIME / Lean Manufacturing
Reduced energy consumption per product Lower operating costs Improved manufacturing productivity Reduced inventory Reduced floor space Reduced waste Safer and cleaner workplace
Who Can Participate?
UI and CL&P manufacturing/industrial customers
Ideally have annual consumption greater than 500,000 kWh
Below 500,000 kWh can apply
Program Incentives
Events 1 and 2 - 100% funded by CEEF Events 3 and 4 – 50% funded by CEEF Other events – customer funded
PRIME Event Characteristics Team selection Half day lean training Value stream mapping (VSM) Kaizen 5S and other lean concepts Implement process improvements identified in VSM Preparation of daily report to management Preparation of final summary report to management
Percent of workplace affected Energy savings calculations Environmental and staffing impact
Document all non-electric benefits where applicable
Program Procedures Vendor solicits eligible participants and identifies
potential kaizen events Customer’s electric usage will be provided to Vendor
after approval by customer Customer and event must first be qualified by Vendor
and UI or CL&P Targeted net cost per lifetime kWh saved
($0.06/lifetime kWh) Vendor uses pre-qualification spreadsheet
Vendor prepares and presents PRIME contract to customer, copy to UI or CL&P
Program Procedures Each event is qualified individually UI or CL&P to review contract and qualification
sheet Lean event conducted (3.5 days)
Team formed Lean event close-out – last day of the event
Kaizen Activity Sheet Energy Savings Calculation Sheet
Vendor completes PRIME activity report and sends to UI or CL&P
Program Procedures
90-day follow-up visit scheduled with Utility Rep and CustomerVendor submits report on progress and
conditionsOpportunity to discuss other
programs/services
Deliverables
Kaizen Activity Sheet
Revised Energy Savings Calculation spreadsheet and final productivity summary/justifications
Monthly project report
At end of event
After 90 day review
Monthly
Contact Information
United Illuminating
Connecticut Light & Power
Marissa [email protected]
Rich [email protected]
Carl [email protected]
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Daniel Penn Associates
Daniel Penn Associates, LLC151 New Park Avenue, Suite 106
Hartford, CT 06106860-232-8577
[email protected]@danielpenn.com