Drug Plastics & Glass Company, Drug Plastics & Glass Company, Inc.Inc.

Oxford, IndianaOxford, Indiana

Advancing Manufacturing Summit VIII:Advancing Manufacturing Summit VIII:The Economic and Environmental Benefits of The Economic and Environmental Benefits of

Sustainable ManufacturingSustainable Manufacturing

Wednesday March 25, 2009Wednesday March 25, 2009Purdue University – West Lafayette, IndianaPurdue University – West Lafayette, Indiana

TAP (WIRE) TIME LINETAP (WIRE) TIME LINE Sign on to TAP (WIRE) program (Oct 07)Sign on to TAP (WIRE) program (Oct 07) Initial TAP Plant Visit/Assessment (Nov 07)Initial TAP Plant Visit/Assessment (Nov 07) Plant Energy Team Formed (Nov 07)Plant Energy Team Formed (Nov 07) Metrics for Success (Dec 07)Metrics for Success (Dec 07) WIRE Energy Training (07 & 08)WIRE Energy Training (07 & 08) Implementation of Best Practices (07 & 08)Implementation of Best Practices (07 & 08) Control & Sustainment (08 & Beyond)Control & Sustainment (08 & Beyond)

PROGRAM RESULTPROGRAM RESULTKWhrs/Machine Hrs Ran

100.00

110.00

120.00

130.00

2005 122.63

2006 126.33

2007 121.33

2008 108.87

1

ANNUAL SAVING IN 2008 = $101,180

ENERGY COST SAVINGENERGY COST SAVING INITIATIVES INITIATIVES

AIR COMPRESSORSAIR COMPRESSORS VFD (CHILLED & TOWER WATER)VFD (CHILLED & TOWER WATER) LIGHTING (T-5 FIXTURES)LIGHTING (T-5 FIXTURES) HVAC HVAC MOTORSMOTORS MATERIAL HANDLINGMATERIAL HANDLING WASTE REDUCTION (RECYCLING)WASTE REDUCTION (RECYCLING)

AIR COMPRESSORSAIR COMPRESSORS• Audit for air leaks on Audit for air leaks on

monthly schedulemonthly schedule• Replaced air cooled Replaced air cooled

compressors with water compressors with water cooled unitscooled units

• Purchased air sequencerPurchased air sequencer• Adopted pro-active & Adopted pro-active &

predictive maintenance predictive maintenance programprogram

• Replaced bad pipingReplaced bad piping

BEFORE = 7 ATLAS AIR BEFORE = 7 ATLAS AIR COOLED TOTAL 310 HPCOOLED TOTAL 310 HP Maximum OutputMaximum Output

NOW = 2 KAISERS WATER NOW = 2 KAISERS WATER COOLED - COOLED - 175 HP175 HP

LIGHTING (HID VS T-5)LIGHTING (HID VS T-5)

REPLACED 105 HIGH BAY LAMPS WITH T-5 FIXTURES

HVAC (Moisture On Roof)HVAC (Moisture On Roof)IR CameraIR Camera

PREMIUM VS STANDARD PREMIUM VS STANDARD EFFICIENCY MOTORSEFFICIENCY MOTORS

WHAT WE LEARNEDWHAT WE LEARNED OVERCOMING THE SKEPTICSOVERCOMING THE SKEPTICS

SIX SIGMA APPROACH (DATA DRIVEN)SIX SIGMA APPROACH (DATA DRIVEN) TRAINING & MORE TRAININGTRAINING & MORE TRAINING PLANNING & EXECUTIONPLANNING & EXECUTION

MEASURE TWICE CUT ONCEMEASURE TWICE CUT ONCE GET THE RIGHT PEOPLE ON THE TEAMGET THE RIGHT PEOPLE ON THE TEAM

CONTROL & SUSTAINCONTROL & SUSTAIN INVOLVE HOURLY PERSONNELINVOLVE HOURLY PERSONNEL CONTINOUS TRAINING & IMPROVEMENT CONTINOUS TRAINING & IMPROVEMENT DEVELOP A SYSTEM OF SELF AUDIT DEVELOP A SYSTEM OF SELF AUDIT ENERGY METRICSENERGY METRICS

QUESTIONS?QUESTIONS?

THANK YOU…..THANK YOU…..