A2A Training Modules 6 to 10

8/20/2019 A2A Training Modules 6 to 10

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This module introduces the management assessment tool. It includes a video to

demonstrate how to fill in the tool, and some examples of management best practices.

Since this tool is very simple and easy to use, there is no exercise for this module.

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The purpose of the energy management assessment questionnaire is to evaluate the

implementation of energy management best practices in an organization. This sets the

context for taking steps to improve Energy Management at both the corporate and

facility level with the additional support provided by the Energy Efficiency and

Management Plan and Action Plan tool.

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The energy management best practice (MBPs) assessment is part of the first step in the

Continuous Improvement Cycle.

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The questionnaire organizes management best practices into a set of seven categories

as shown in this slide —each of which implies roles, responsibilities, procedures and

competencies. The management best practice analysis is applied at two levels:

corporate level and plant level.

Additional information on the quality systems in the plant is also gathered, which will tie

into the productivity improvement system assessment.

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The above exhibit illustrates the layout of the Management Best Practice Assessment

tool, as shown in the index tab.

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Link:

Module 6 Video

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Link:

10 A2A Training Module 6 activity –

Completed Assessment

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Some examples of corporate management practices are given in this slide. Consider why

each measure is management best practice and how each measure can be a benefit to

an organization and an industrial facility.

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Some examples of facility management practices are given in this slide. Consider why

each measure is management best practice and how each measure can be a benefit to

an organization and an industrial facility.

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Similar to the management assessment, the productivity is very simple and easy to fill

in. This short module explains the purpose of the productivity improvement tool, and a

brief demonstration will show how to use it.

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The purpose of the Productivity Improvement Assessment questionnaire is to evaluate

the implementation and awareness of continuous improvement practices in an

organization. This sets the context for taking steps to improve productivity with the

additional support provided by the Energy Efficiency and Management Plan and Action

Plan checklist and template tool.

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The Productivity Improvement Assessment (PIA)is the last of the assessment tools which

make up the first step in the Continuous Improvement Cycle.

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This assessment is that last step the toolkit takes before identifying opportunities at the

factory.

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The above exhibit illustrates the layout of the Productivity Improvement Assessment

tool as shown in the index tab.

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Link:

Module 7 Video

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Link:

11 A2A Training module 7 –

PIA

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This module explains the content of the report card and opportunity identification tool,

and how to use it. The previous modules have shown how to use the input tools

(technical assessment, management assessment and productivity tools) and reference

tools (the technical libraries). Now you will see how they all feed into the RCOI tool, and

how the RCOI organizes and summarizes the data to produce relevant graphs and tables.

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The Report Card and Opportunity Identification tool imports data from the assessment

tools, performs calculations to analyse and summarize the data, and presents the results

by means of graphs, charts and tables. The result is a report card which displays a

breakdown of energy consumed, technical and best practice scores, and a summary of

prioritized energy management opportunities and their potential savings.

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As shown above, the Report Card and Opportunity Identification tool falls under the

second step of the Continuous Improvement Cycle.

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The above exhibit illustrates the layout of the Report Card and Opportunity Identification

tool as shown in the index tab. Users can click on the description to navigate directly to

that tab.

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As mentioned, the benchmarking study addresses three elements: energy use and

efficiency, technical best practices, and management best practices. The report card

present results and scores of each of these elements.

Here is the typical output of the first element: energy use and energy efficiency. The

charts indicate the annual purchased energy costs and the corresponding net energy

content. The table shows the resulting energy output by end use (consumed energy).

For some plants who are unaware of their energy performance, this can be quite

revealing and surprising to learn where their energy is going. Energy intensity metrics

are usually provided if a specific subsector is studied (such as GJ per ton of product item

for ammonia production).

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1 Comfort energy includes energy used for heating, ventilation, air conditioning and

lighting

Energy Intensities.2 European Directive on Integrated Pollution Prevention and Control (IPCC): Best

Available Technologies (does not include energy used for comfort)

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The second dimension of the energy performance benchmarking is an assessment of technicalbest practices.

Here is an example of results of implemented best practices. Best practices are assessed by eachend use or major category of equipment, and an overall average TBP score is provided at theend. In assessing best practices, only applicable practices are included. For example, if there are23 best practices for ovens, and 19 are applicable to a plant, and they have implemented 12 ofthose practices, their score is 12 out of 19, or 63%.

The benchmarking reveals the baseline of energy performance and also the opportunity forimprovement. As shown, for boilers, 50% of applicable best practices are implemented in thisexample, leaving another 50% of applicable practices yet to be implemented. For major end useslike boilers, this can be important in reducing energy use.

On the bottom of this slide is another example of the output of results for implemented bestpractices. Management Best practices are assessed by each major category of equipment, andan average MBP score is provided at the end.

These best practices are listed in order of what is considered to be most important or strategic indriving MBPs forward from policy and planning, organization and accountability, financing,project management, monitoring, reporting and communication and finally training, capacitybuilding and recognition. Having an appropriate policy and plan in place (appropriate to the sizeof the organization and its objective) drives improvements in other categories of MBPs. Manyplants tend to focus on energy management on an ad-hoc basis, such as project financing ofenergy improvement projects as needed. Without an appropriate plan, evaluation plan andtraining in place, projects may not address or achieve their expected performance or sustain

energy performance in the long term.

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This table summarizes the opportunities, providing just the name of the each measure.

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The opportunities are also listed showing more detail, including the potential energy,

greenhouse gas and cost savings for each measure.

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The measure library tab number is also provided, so if more detail for a measure is

required, go to the given library tab to find more information.

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All variables are automatically imported from the Technical Assessment and

Management Assessment tools, and the measure library. There is no requirement to

gather and enter data for this tool. However, it is recommended that the imported data

be verified.

This toolkit imports data and finally summarizes the data in a concise and coherent plant

report card.

•The answers from the Technical Assessment and Management Assessments

tools are imported into “RC 6” and “RC 7” tabs where the scores are calculated.

•The energy use for each end-use is imported from the Technical Assessment.

•The tool calculates best practices scores and uses them together with energy

use by end use to determine energy savings potential for each end-use, and toprioritize the opportunities.

•The report card (“RC 1”) displays these results in the form of charts and tables.

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Link:

Module 8 Video

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Links:

12 A2A Training module 8 activity

05 A2A Training module 5.1 activity - Completed Assessment

10 A2A Training module 6 activity - Completed Assessment

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Links

13 A2A Training module 8 activity - RCOI - Blank

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This slide shows some of the results from the completed report card. The completed

reported card is also included in the exercise folder (“14 A2A Training module 8 activity -

RCOI – Completed”)

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This module explains the Action Plan tool which addresses planning and deliverables.

We have seen the input tools which are used to gather information from a plant, which

then feed into the report card and opportunity identification tool which summarizes that

data and illustrates the results in relevant ways that aid in determining next steps. The

Action Plan tool is a template to help an organization or facility ensure that the

continuous improvement process does not stop after the assessment, but carries on to

implementation.

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The purpose of the Energy Efficiency and Management plan checklist and Action Plan

template is to assist an organization in developing an Energy Management Plan, and

setting priority and defining responsibility and a timeline for carrying out activities to

achieve and sustain energy efficiency improvement while considering productivity

improvement aspects.

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The results of the Report Card and Opportunities Identification tool are used to

complete the EE&M Plan checklist. The prioritized elements of the EE&M Plan Checklist

are used to prepare an action plan to implement the opportunities, using the EE&M

Action Plan template.

The checklist and action plan are templates to be filled in manually. They are not linked

to other tool elements as is the case for the report card and identification tool.

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The questionnaire lists elements to consider when developing and implementing both

an energy management plan and an action plan. The identified opportunities resulting

from using the previously discussed tools, are to be included in the development of the

plans. The plans are developed in consultation and collaboration with the plant, and may

require a number of meetings to be developed and completed.

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Link:

Module 9 Video

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The categories of the EE&M Plan align with the management best practice assessment

tool.

The EE&M Action Plan is completed with manual input from both the EE&M Plan

Checklist and the Report Card and Opportunity Identification tools. The high priority

elements defined in the EE&M Plan Checklist, followed by the medium and low priority

elements, are manually transferred to the Action Plan (tab AP 4). The energy

management elements are captured in the first eight action item categories, as shown

on the above slide.

The ninth and last action item category is for the technical best practices opportunities.

Here the technical best practices opportunities identified in the Report Card andOpportunity Identifications (RCOI) are manually transferred. The RCOI list the

opportunities by end uses, and include the cost savings, relative implementation cost

and relative implementation difficulty. All these elements are manually copied by the

user from the RCOI to the Action Plan together with the applicable library reference and

description. The user needs to prioritize the list by arranging the opportunities by each

end use starting with the opportunity that has the largest energy savings first, followed

sequentially with the opportunities with lower energy savings and ending with the

opportunity with the smallest energy savings. The user highlights in yellow the four

opportunities that has the largest energy savings.

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Once the EE&M Action Plan template is completed, it is recommended that the

prioritized actions are reviewed, and discussed with senior management. Responsibility

can then be assigned to personnel who will ensure that the action is carried out, as well

as a scheduled date for the completed action. This task is accomplished working in

consultation with the enterprise. This action plan allows entry of the status of updates

to be carried out after monthly, semi-annual or scheduled review. The action plan is a

working document and needs to be revised and updated in a collaborative effort

between the user and the enterprise.

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The technical best practices opportunities identified in the Report Card and Opportunity

Identifications (RCOI) are manually transferred to the Action Plan Template. The RCOI

lists the opportunities by end uses, and include the cost savings, relative implementation

cost and relative implementation difficulty. All these elements are manually copied by

the user from the RCOI to the Action Plan together with the applicable library reference

and description. The user needs to prioritize the list by arranging the opportunities by

each end use starting with the opportunity that has the largest energy savings first,

followed sequentially with the opportunities with lower energy savings and ending with

the opportunity with the smallest energy savings. The user highlights in yellow the four

opportunities that has the largest energy savings.

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To see the answers, open the file: 15 A2A Training Module 9 activity Action Plan or click

the following link:

15 A2A Training Module 9 activity Action Plan

Answers to questions are in the footnotes of AP4 (of A2A Action Plan).

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Answers to questions are in the footnotes of AP4 (of A2A Action Plan)

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Links:

15 A2A Training Module 9 activity Action Plan

Note: once completed you can view the completed action plan by opening the file: “16

A2A Training Module 9 activity Action Plan – Completed” or clicking the following link:

16 A2A Training Module 9 activity Action Plan - Completed

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This module is only relevant for trainees who will work as consultants with an industrial

facility or company. It includes ideas and tips on effective ways of presenting the results

of the A2A Toolkit assessment to a company, and more generally, how to effectively

communicate and collaborate with a plant.

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Think about your response to these questions and then proceed to the next slide for

some ideas about potential answers.

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Think about your response to these questions and then proceed to the next slide for

some ideas about potential answers.

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Documents

A2A Training Modules 6 to 10