Lean Energy Use

Lean Energy Use

(Parte 1 de 11)

Achieving Process Excellence Using Less Energy

The Lean and Energy Toolkit

w.epa.gov/lean

Toolkit Format and Icons The toolkit uses icons in the page margins to help you fi nd and follow important information in each chapter.

Key Point Identifi es an important point to remember

Key Term Defi nes an important term or concept

New Tool Presents a technique or resource that helps capture, communicate, or apply new knowledge

How-to Steps Describes sequenced actions to implement a tool

Chapters also include one or more “To Consider” text boxes that contain questions to help you explore how the information relates to your organization.

Lean and Energy Toolkit

Acknowledgments

The U.S. Environmental Protection Agency (EPA) is grateful for the invaluable assistance of the organizations and individuals who helped develop this toolkit and shared experiences, tools, and techniques for integrating Lean manufacturing and energy management efforts.

EPA’s Lean and energy partners include Baxter International, California Manufacturing Technology Consulting (CMTC), Eastman Kodak Corporation, Eaton Corporation, General Electric (GE), HNI Corporation, the National Institute of Standards and Technology (NIST) Manufacturing Extension Partnership (MEP), and the U.S. Department of Energy. The EPA’s National Center for Environmental Innovation and the Offi ce of Pollution Prevention and Toxics participated in the development of this toolkit.

In addition to these organizational partners, this toolkit has benefi ted from the collective expertise and ideas of many individuals. In particular, EPA would like to thank the following individuals for their thoughtful contributions:

Susan Boone, Lean Six Sigma Trainer, GE Infrastructure

James Breeze, Energy Engineer/Project Leader, Worldwide Energy Offi ce, Eastman Kodak Company

Jenni Cawein, Corporate Environmental Health and Safety (EHS) Engineering Manager, Baxter International

Gerald Church, Director of Energy Services, CMTC Rob Currie, Director, Corporate EHS Engineering, Baxter International Gretchen Hancock, Project Manager, GE Corporate Environmental Programs Ernie Kulik, Corporate EHS, Eaton Corporation Scott Lesnet, Member EHS Manager, HNI Corporation Kirk Prather, Operations Manager Energy Services, CMTC

Douglas W. Prihar, Management Assistance Partnership Project Director, Nevada System of Higher Education

Randy Shultz, Facilities and EHS Manager, Eaton Truck, Shenandoah, Iowa

Scott Summers, Director and Vice President, EHS, Film Products Group, Eastman Kodak Company

Carroll Thomas, Partnership Catalyst, NIST MEP Joe Wolfsberger, Vice President of Corporate EHS, Eaton Corporation

This toolkit was prepared for the U.S. Environmental Protection Agency by Ross & Associates Environmental Consulting, Ltd. (http://w.ross-assoc.com) in association with Industrial Economics, Inc. (EPA Contract # EP-W-04-023).

Lean and Energy Toolkit

Executive Summaryi
Prefacei
Purpose of This Toolkiti
Key Questions Addressed by This Toolkiti
Chapter 1 Introduction1
Benefi ts of Coordinating Lean and Energy Management1
Strategic Lean and Energy Management5
Chapter 2 Overview of Energy Use and Lean9
Energy Sources and End Uses9
Understand the Costs of Energy Use12
Energy Effi ciency Benefi ts of Lean Implementation13
Chapter 3 Energy Assessment Strategies15
A. Walk Through Processes to Observe Energy Use15
B. Energy Audits and Measuring Energy Use16
C. Examine Energy Use with Value Stream Mapping18
D. Use Six Sigma to Find and Eliminate Energy Waste and Variation2
E. Conduct Energy Kaizen Events2
Chapter 4 Energy Reduction Tools and Strategies25
A. Use Total Productive Maintenance to Reduce Equipment Energy Waste25
B. Replace Over-Sized and Ineffi cient Equipment with Right-Sized Equipment28
C. Design Plant Layout to Improve Flow and Reduce Energy Use29
D. Encourage Energy Effi ciency with Standard Work, Visual Controls, and Mistake-Proofi ng30
Chapter 5 Conclusion3
Lean Windows of Opportunity for Energy Savings3
Going Even Further with Clean Energy34
The Lean and Energy Journey34
Appendices37
Appendix A Energy Assessment Service Providers, Resources, and Tools37
Appendix B Sector-Focused Energy Reduction Resources41

Table of Contents

Appendix C Energy Conversion Resources and Rules of Thumb for Estimating Energy Cost Savings ..............................................................................................43

Lean and Energy Toolkit

Benefi ts of Coordinating Lean & Energy Management (Box 1)1
Lean and Energy Use Reduction: Company Cost Savings Experience (Box 2)3
Lean and Energy at Toyota (Box 3)4
Why Be Strategic about Energy Management? (Box 4)5
Energy End Uses: What Do We Use Energy to Do? (Box 5)10
Questions for Understanding Energy Use (Box 6)15
Energy Treasure Hunts at General Electric (Box 7)16
Energy Savings From “Lean and Clean” Assessments (Box 8)17
Common Energy Units (Box 9)17
Example Results from Value and Energy Stream Mapping Projects (Box 10)19
Six Sigma and Energy Savings at Baxter International (Box 1)2
What is an Energy Kaizen Event? (Box 12)23
What is TPM? (Box 13)25
Four Strategies for Integrating Energy-Reduction Efforts into TPM (Box 14)26
and Process Heating Systems (Box 15)27
Over-Sized Equipment (Box 16)28
Three Ways to Right Size Your Fan System (Box 17)29
Flow and Energy Use (Box 18)29

Boxes Energy-Reduction Checklists for Combustion, Steam Generation,

Share of Energy Consumed by Major Sectors of the U.S. Economy, 2005 (Figure 1)2
Lean and Energy Management Roadmap (Figure 2)6
Sources of Energy Used for U.S. Industry and Manufacturing, 2005 (Figure 3)9
Example Value Stream Map (Figure 4)20
Example Process Data Box with Energy Use Data (Figure 5)21
Example Visual Control (Figure 6)30
Dashboard Visual Controls (Figure 7)31

Figures

Tables Table 1: Manufacturing Sector Inputs for Heat, Power, and Electricity Generation by End Use .1

Table 2: Electrical Power Bill Analysis Worksheet13
Table 3: Energy Use Hidden in Lean Wastes14

Table 4: Example Actions Identifi ed at a Kaizen Event .................................................................24

Executive Summary

Executive Summary

The U.S. Environmental Protection Agency (EPA) developed this Lean and Energy Toolkit to assist organizations in reducing energy use and improving performance through Lean manufacturing— the production system developed by Toyota. Drawing from the experiences and best practices of multiple industry and government partners, this toolkit describes practical strategies and techniques to improve energy and environmental performance while achieving Lean goals such as improved quality, reduced waste, and increased customer responsiveness.

There are at least three reasons for integrating Lean and energy effi ciency efforts:

1. Cost Savings: Reducing energy costs has a signifi cant impact on business performance, though costs may be hidden in overhead or facility accounts.

2. Climate Change and Environmental Risk: Proactively addressing the environmental and climate impacts of energy use is increasingly important to industry and society. Failure to do so is a potential business risk.

3. Competitive Advantage: Lowering recurring operating costs, improving staff morale, and responding to customer expectations for environmental performance and energy effi ciency increases your competitive advantage.

Linking Lean and Energy Use

Considerable energy savings typically ride the coattails of Lean activities because of Lean’s focus on eliminating non-value added activities (waste). Without explicit consideration of energy wastes, however, Lean may overlook signifi cant opportunities to improve performance and reduce costs. Companies such as Baxter International, Eastman Kodak, General Electric, Toyota, and 3M, as well as many smaller manufacturers, have successfully used Lean methods to reduce energy use, risks, and costs (see textbox).

Example Results From Lean and Energy Improvement Efforts

✓ A Baxter International facility saved $300,0 in energy costs in one year.

✓ General Electric has reduced greenhouse gas emissions by 250,0 metric tons and saved $70 million in energy costs since 2005 at facilities worldwide.

✓ Toyota Motor Manufacturing North America reduced facility energy use and greenhouse gas emissions by 30 percent per vehicle since 2000.

This toolkit describes a range of strategies for identifying Lean and energy improvement opportunities and reducing energy use with Lean methods. It is not necessary to implement all the techniques in the toolkit to succeed; instead, select and adapt the approaches that make the most sense for your organization.

Executive Summary

Lean and Energy Assessment Strategies

Lean and energy assessment strategies involve observing shopfl oor activities to identify signs of energy waste, measuring actual energy use and costs over time, and implementing energy savings opportunities through short, focused events. Strategies described in this toolkit include:

• Energy Treasure Hunts: Conduct a three-day plant-wide assessment of energy savings opportunities using a cross-functional team of employees.

• Value and Energy Stream Mapping: Integrate energy-use analysis into the Lean value stream mapping process to identify improvement opportunities within the context of the entire “value stream” of a product or service.

(Parte 1 de 11)

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