Alabama

What is E3?

• A DOE, an EPA, a MEP, and a SBA guy walk into a bar…

• All realize they are trying to help manufacturers separately

• Status quo was disruptive and time consuming

• Eureka!! – Why don’t we work together!?!

What is Alabama E3? • Collaboration among 25 local and state

government, federal agencies, utility companies, associations, non-profits, and manufacturers working together to promote sustainable manufacturing

Alabama E3 Partners • Alabama Technology

Network (ATN)

• Alabama Industrial Assessment Center (IAC)

• ADECA – Energy Division

• Appalachian Regional Commission

• Small Business Development Center

• Tennessee Valley Authority (TVA)

• Alabama Power Company

• Alabama Gas Corporation

• Waste Reduction and Technology Transfer Foundation (WRATT)

• City of Tuscaloosa

• City of Montgomery

• City of Huntsville

• Business Council of Alabama (BCA)

• Manufacture Alabama

• Small Business Administration

Alabama E3 Partners/Supporters

• NIST MEP (U.S. Dept. of Commerce)

• U. S. Department of Energy

• U. S. Environmental Protection Agency

• U. S. Department of Labor

• Alabama Community College System (Office of Workforce Development)

• Alabama Automotive Manufacturers Association (AAMA)

• ZF Industries

• U.S. Mercedes Benz Int.

• Economic Development Partnership of Alabama (EDPA)

• Alabama Industrial Development & Training (AIDT)

• Alabama Aerospace Industry Assn. (AAIA)

• Clients

Engaging Partners

• Utilities – Notify the local utility of engagement – Provide billing information – Identify incentives that exist – Source of technical know-how

• ADECA and other funding sources – Notify of potential qualifying projects for Alabama SAVES – Identify and obtain grants to fund activities

• EDA and other associations – ED markets and recruits companies to participate

• MEP, EPA, and DOE – Share lessons learned and training

What Does E-3 Stand For?

• Environment

• Energy

• Economic Impact

Learning to See

• Defects

• Overproduction

• Waiting

• Not Using KSAO’s

• Transportation

• Inventory

• Motion

• Excess Processing

• Water Pollution and Disposal

• Air Emissions

• Solid Waste and Scrap

• Toxic Chemicals and By-Products

• Energy

8

1) Assessment Tools

• Greenhouse Gas Calculator • Pollution Prevention Tools • Safety Assessment • Lean Assessment • Energy Best Practices Audit • Industrial Assessment Center • Lean and Green VSM • Waste Stream Mapping • DOE Software Tools

– ePEP

2) Employee Development • Assessment uncovers training needs

– Practical Energy/Best Practice

– Industrial Maintenance Training

– Purdue University Green Enterprise

– Rapid Improvement Workshops

– Management Systems

– Lean Training

– Quality Training

– Safety Training

Measureable Impacts

Energy Metrics:

Environment Metrics:

Economic Metrics:

• Environmental savings identified

• Lean savings identified

• Other cost savings

• One time potential cost savings identified

• Individuals trained

• Jobs created

• Jobs retained

• Total annual potential impact identified

• Number of small businesses engaged

• Percentage of small businesses engaged

• Number and value of SBA loans granted

• Capital infusion dollars invested

• Hours of counseling provided

• Air emissions reduced (lbs)

• Solid waste reduced (lbs)

• Material intensity per unit of production

• Hazardous waste reduced (lbs)

• Hazardous materials reduced (lbs)

• Water pollution reduced (lbs)

• Water used/conserved (gal)

• Water intensity per unit of production

E3 Metrics

• Energy conserved (MM BTU/kWh)• Energy intensity per unit of production• Carbon reductions (tons)• Carbon intensity per unit of production

2222

3) Growth Services

• Innovations Engineering

– IE Jump Start

– IE Leadership Institute

– Coaching and mentoring

– http://innovationengineering.info/

4) Waste Reduction Implementation

• Lean and Green VSM • Waste Stream Mapping • Technical Assistance for Capital Projects • Rapid Improvement Workshops • Suggestion Programs • Six Sigma Projects • Energy Treasure Hunts • Energy Kaizen Events • Total Productive Maintenance (TPM) • Right-size Equipment • Plant Layout and Flow • Standard Work, Visual Controls, and Mistake Proofing

Implementation Project Highlights

• Work Method Kaizen – Autoclave optimization – Oven optimization – Workstation optimization – Changeover reduction

• Facilities Enhancements – Several compressed air tagging and repair activities – Lighting proposals and justifications – Plant expansion optimization and layout

improvements

Sample Projects

Six Sigma

© University of Alabama in Huntsville

THEME (Purpose / Background)

OBJECTIVES (Goals & Targets)

CURRENT SITUATION / STATUS (Data) Unresolved Items:

IMPLEMENTATION PLAN & STATUS Legend: G On Schedule Y Problems R Late

20 40 60 80 100

WHO 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4

ANALYSIS / ROOT CAUSES (5 Whys / Fishbone)

Due Date% Complete

Make decision to continue

Use IBA analyser

Evaluate fuel consumption

Make decision to continue

5 Measure scale loss during steady state (180 - 215 minutes)

WHAT

Make decision to continue

3 Implemement delay strategy for furnace 1 and 2

4 Reduce the time charge and discharge doors stay open

Any items that need follow-up or support from others (e.g. items outside your control).

2 increase furnace pressure from 0.9 to 1.0

1 increase furnace pressure from 0.8 to 0.9

Evaluate fuel consumption

Check furnace outside wall temperature

Analysis of current state. Why does a gap exist against the objectives above. Spend appropriate time

at this phase. Ask "why" five times or develop a fishbone diagram to determine root cause.

Evaluate fuel consumption

Check furnace outside wall temperature

Make decision to continue

Evaluate fuel consumption

Measure scale loss during delays(>= 360 minutes)

A3: Furnace 1 OptimizationTO: Corey Springman, Christoph Evers,

Markus Forsch, Larry WahlFROM: xxx, xxx, xxx

State the purpose of this report / project. (Does it identify a need or problem?).

Optimize Furnace #1's atmosphere in order to reduce the cost of reheating slabs. This entails:

1. Reduce annual consumption of natural gas

2. Measure oxidation of slabs from downstream delays

List key objectives. State improved / future state desired conditions.

1. Reduce natural gas consumption by 1% as measured by the monthly "Fuel Rate GJ/Ton

(WOD)".

* Select best unit of measure e.g "Fuel m3 WOD" to measure reduction in fuel consumption

despite delays or an increase in the number of slabs discharged.

2. Measure the yield loss (from oxidation) due to downstream mill delays. This includes

developing and validating a procedure to measure yield loss from the furnace.

COUNTERMEASURES: PROPOSED ACTIONS / ITEMS / STRATEGIES (Rationale)

Date Started: xx/xx/20xx Revision: 0

Production Report for Furnace #1

Energy Treasure Hunts

© University of Alabama in Huntsville

Energy Kaizen Event

© University of Alabama in Huntsville

Air Leak Tagging and Repair

Lighting Project Justifications

Plant Layout and Flow

Standard Work

© University of Alabama in Huntsville

Press Brake Changeover Procedures1 Put press in manual mode, lower ram to within 1/16" of bottom die, and loosen top &

bottom die holder bolts.

2 Remove punch and die from press and place in proper rack location. Manually enter

new tooling height into control, then retrieve new punch and die from die rack and

place in press (Note: use jib crane if needed)

Lower ram before loosing die bolts

Loosen die bolts using impact Put press in

manual mode

Place removed tooling in proper rack location

Retreive new tooling from rack and place in

press

Manually enter new tooling height into

• Paper

• Glass

• Metal

• Plastic

• Electronics

• Organic

• Construction/

Demolition

• Hazardous

• Special/Universal

• Mixed Residue

Solid Waste: Zero Landfill Initiatives

• 37 Energy assessments completed

• 37 Lean assessments completed

• 40 Lean and energy implementation events (kaizens) held

• 4 E3X projects completed and 5 underway

• Total Energy Savings Opportunities Identified: $3,364,835

• Average Energy Savings Opportunities Identified: $105,151

• Actual Energy Savings resulting from implementation projects: $1,073,744 (14,363,383 kWh annual savings and 9883 tons of CO2 reduction annually)

• Total Reported Impact from implementation events: $1,506,238

• Lost count on the number of people trained!!

E3 Impacts to Date

E-3 Client Impact Video

QUESTIONS

Discussion

&

Alabama Technology Network E-3 Program Overview

http://AlabamaE3.org

Anthony Holden anthony.holden@uah.edu

256-824-6289

Wayne Jackson, CEA wjackson@atn.org

256-310-4990