svr presentation 2016
TRANSCRIPT
WORLD CLASS MANUFACTURING
Energy Efficiency Project (Energy CD)
Michael Lentz 1Facilities Engineering SVR
10 WCM Pillars
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Why Are We Here?
JNAP Total Perimeter Costs $395.8M
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6.5% of Perimeter Costs
Why Are We Here?
$-
$500,000
$1,000,000
$1,500,000
$2,000,000
$2,500,000
$3,000,000
$3,500,000
$4,000,000
$4,500,000
Top Causal By Loss Type
Compressed Air
HVAC
Building Electricity
Process Chilled Water
Process Hot Water
Process Natural Gas
Process Electricity
$-
$500,000
$1,000,000
$1,500,000
$2,000,000
$2,500,000
$3,000,000
$3,500,000
Top Causal Losses by Vector
Energy Source/TypeLoss
Transmission andLeakage Losses
Not Using RecoverableEnergy Losses
Over Consumption
Non Optimization
Tranformation Losses
Useless Consumption
Useless Consumption Breakdown
HVAC $1,180,202
Process Electricity $1,303,406
Process Natural Gas $667,527
Compressed Air $164,000
Building Electricity $298,290
Process Hot Water $54,162
Process Chilled Water $42,156
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What is the Goal
• Reduction in Energy Consumption
• Target is 5.98 GJ/Unit by 2020
Source2009
Actual
2010
Actual
2011
Actual
2012
Actual
2013
Actual
2014
Actual
2015
Actual
Electricity 5.85 4.09 2.39 2.11 1.88 1.73 1.71
Natural
Gas12.46 9.02 5.90 4.81 5.07 4.86 4.38
Total
Energy18.32 13.10 8.28 6.92 6.95 6.59 6.09
* All numbers are in GJ/Unit 5
WCM Tools (5W1H)
Initial Description of the Problem: Excessive useless consumption of plant energy.
What* What does the problem look like? What product, machine, material was being used? What size?
Plant useless energy consumption is a top loss.
When * When did the problem occur? When in the sequence of operation; startup, continuous running, intermittent problem, shutdown, changeover?
The problem occurs during continuous running of vehicle assembly.
Where* Where did you see the problem? Where on the equipment or material did you see the problem?
The problem has been observed in all areas of the plant.
Who* Who does it affect? Everyone? Or is it less of a problem for some individuals or teams? (If so, what info can they offer?) Is it skill related?
All shifts contribute to the useless consumption of energy.
Which* Which trend or pattern does the problem have? E.g. Is the problem more frequent on Monday mornings? After a change-over? Or is it random in nature? Which direction does the problem happen in? (Note: Not many problems are truly random!)
This problem is typically observed when the line is stopped. IE. Between shifts, break times, starved/blocked states.
How* How is the state of the equipment changed from the optimal? How many times does the problem occur?
Useless consumption of energy is considered a waste and therefore unethical.
Plant useless energy consumption is a top loss. The problem occurs during continuous running of vehicle assembly. The problem has been observed in all areas of the plant, and all shifts contribute to the useless consumption of energy. Mainly between shifts, during downtime, and blocked/starved states. Useless consumption of energy is considered a waste and therefore unethical.Revised Description of the Problem: The plants useless energy consumption is a top loss. The problem occurs during continuous running of vehicle assembly. The problem has been observed in all areas of the plant. All shifts contribute to the useless consumption of energy, but specifically between shifts, during downtime, and blocked/starved states.
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WCM Tools (4M)
Problem
Current method of data stratification is insufficient
Not all machines are usingideal energy saving methods
Material
MachineMan
Method
HVAC Schedulers not functions
Clogged HVAC filters minimize air delivery
Operators not turning off their machines
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WCM Tools (5 Why)
Problem Description
Potential Phenomena
1st Why 2nd Why 3rd Why 4th Why 5th Why Countermeasure
Plant useless energy consumption is a top loss. The problem occurs during continuous running of vehicle assembly. The problem could not be centralized, and affects everyone. Mainly between shifts, during downtime, and blocked/starved states. As a plant we should not be paying for energy that is not used to produce vehicles. Waste is fundamentally unethical.
Not allMachines areusing ideal energy saving methods. (VFDs, sleep mode…)
Machines uselesslyconsuming energy have not been modified for ideal energy consumption.
Machines uselesslyconsuming energy are not identified.
Current energy CD doesn’t allow to simply & accurately identify machines uselessly consuming energy.
CurrentCD is outdated and lacks desired detail.
Expand current energy CD. Complete thorough and detailed energy CD per team area to allow future projects to accurately, and efficiently attack useless consumption.
CountermeasureExpand current energy CD. A complete, thorough, and detailed energy CD per team area to allow future projects to accurately, and efficiently attack useless consumption.
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The Project (Overview)
• Collected data on equipment throughout the plant
– Equipment gathered consumes energy
• Forms of energy that we looked at:
– Compressed Air
– Electricity
– Natural Gas
• Follow Electrical Equipment back to the Bus level.
• Took measurements on the equipment to understand how it was consuming energy.
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In Cycle
Between Cycle
Line Block
Preferable Measurement Plot
Total Pieces of Equipment Per Center
• These Pieces of Equipment are Consumers of Energy:– Pieces of Equipment Total in BIW:
• Process Equipment: 1629
• HVAC Equipment: 235
• Dock Doors/Heaters: 44
– Pieces of Equipment Total in Paint:• Process Equipment: 2303
• HVAC Equipment: 646
• Dock Doors/Heaters: 14
– Pieces of Equipment Total in TCF: • Process Equipment: 1533
• HVAC Equipment: 162
• Dock Doors/Heaters: 69
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Tracking Back to the Bus Level
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Column Matrix Fed from Bus or panel MACHINE # of Mach DEVICE ID Device Description Energy Type ProcessAdditional Comments
[T2:T3 ; U2:U3] Panel @ V-3 Rotary Lift Hoist 1 AAA379680 LiftCompressed
Air & ElectricityBrake
Reprocess
[U3:U4 ; V3:V4] Panel @ V-3 Rotary Lift Hoist 1 AAA124244 LiftCompressed
Air & ElectricityBrake
Reprocess
U3 Bus Plug @ S-6Repair Area Exhaust
Fan1 000284147 Exhaust Electricity
Brake Reprocess
[T3:T4 ; U3:U4] Panel @ V-3 Rotary Lift Hoist 1 AAA379681 LiftCompressed
Air & ElectricityBrake
Reprocess
[T3:T4 ; U3:U4] Panel @ V-3 Rotary Lift Hoist 1 AAA072087 LiftCompressed
Air & ElectricityBrake
Reprocess
[U2:U3 ; V2:V3] Bus Plug @ S-6 Hoist Panel 1 Panel ElectricityBrake
ReprocessAt Column V-3
A2 Substation
A2B-2 Bus Plug at S-6
Repair Area Exhaust Fan
Hoist Panel
Rotary Lift Hoist
Rotary Lift Hoist
Rotary Lift HoistFeeder Breaker
Metering
Kaizens
• Kaizen IDs:– 110813 – Air Showers to Paint Booths
– 110816 – Air Showers to Paint Booths
– 110818 – Air Showers to Paint Booths
– 110821 – Air Showers to Paint Booths
– 111742 – Air Leaks in Paint
– 111859 – Stair Safety Hazard
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Kaizens 110813, 110816, 118018 and 110821
• These kaizens were used to attack quality issues in the Color Booths in paint
• Each of the booths have blow off chambers before entering the booth.
• Many of the blow offs did not work.
• Inspection showed that they would work if they were reset.
• Long Term Fix:
– Change PLC programming logic to reduce errors
• Short Term Fix:
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Air Leak Kaizen
• Found air leaks throughout BIW, Paint, TCF.
• Sent to environmental so they could be monetized, cataloged, and then fixed.
Screenshot of Catalog
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Other Work/Projects
• Helped Fill in for Facilities Maintenance Supervisors.
• Assisted the Environmental Pillar with Their Air Leak Project.
• ME Compliance Improvements
• Updated the Energy Score Card
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Questions
THANK YOU FOR THE OPPORTUNITY
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