SVR Presentation 2016

WORLD CLASS MANUFACTURING

Energy Efficiency Project (Energy CD)

Michael Lentz 1Facilities Engineering SVR

10 WCM Pillars

2

Why Are We Here?

JNAP Total Perimeter Costs $395.8M

3

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

4

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.

6

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

7

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.

8

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.

9

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



– Pieces of Equipment Total in TCF: • Process Equipment: 1533



10

Tracking Back to the Bus Level

11

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


Reprocess

U3 Bus Plug @ S-6Repair Area Exhaust

Fan1 000284147 Exhaust Electricity

Brake Reprocess



Reprocess



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



– 111742 – Air Leaks in Paint

– 111859 – Stair Safety Hazard

12

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:

13

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

14

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

15

Questions

THANK YOU FOR THE OPPORTUNITY

16

Documents

SVR Presentation 2016