Overview of a SME achieving 3P initiatives.

1. Energy and Environment
•People
•Planet
•Profits

2. 1. Our products-Consumer & Commercial
2. Our corporate strategy
3. Our local strategy
“A society grows great when old
men plant trees whose shade they
know they shall never sit in.”
(Greek Proverb)

3. Building supply dealers & big box stores

4. Advantage ICF System®
Insulated Concrete Forms

5. EIFS-Exterior Insulated Finishing Systems

6. • Show insulspan job site sign
Insulspan-Structural Insulating Panels

7. CORPORATE SUSTAINABILITY

8. From a focus on promotion
of benefits towards ….
Internal sustainability and
external transparency
Sustainable Materials and Processes
Measurement and Reporting
Manufacturing Initiatives
Transparency
Become recognized for your actions
not just your words.
Transition to Sustainability

9. Setting Targets for
Improvement
Reduce energy consumption
Reduce waste output
Reduce emissions to the environment

10. Sustainability - Journey of
Continuous Improvement
Continuous improvement implies a
process without end
Similar to other continuous
improvement processes
– Lean Manufacturing
– ISO
– Six Sigma
Identify, measure, set targets,
implement action, measure, analyze
and set new targets/actions

11. PFB’s Sustainability Committee
Sustainability
Committee
Chair
Economic Sub-
Committee
Product Sub-
Committee
Employees Sub-
Committee
Environmental Sub-
Committee
Product
Responsibility
-Product use & end
life issues
-Digital Information
-Packaging & labeling
Human Rights &
Labour Practices
-Employee
Involvement
-Social Responsibility
-Training
-Policy development
-community Outreach
Environmental
Performance
-Lean Manufacturing
Resource Utilization
-Emissions
-Energy Utilization
Economic
Performance
-Project Analysis &
Justification
-Risk Analysis
-Annual Report

12. Scrap EPS Waste
-one man’s trash is another man’s gold!

13. Scrap EPS Waste
Why is scrap EPS foam sent to
landfill/recycling a problem?
– Its worth something, EPS waste = $
• Energy to produce the material
• Transportation to recycling
• Manpower to move and load it
• Space to store it
Poor image to portray
Not consistent with sustainability
2012 Kitchener used 400,000 lbs of regrind

14. Plant Level Initiatives
Sustainable Lean Manufacturing
Energy & Environment
1.Electricity
2. Natural Gas
3. Water
4. Secondary Fuels

15. Waste Type Examples Environmental Impacts
Defects Scrap, rework, replacement production,
inspection
-Raw material consumed in making defective products
-Defective components require recycling or disposal-process
energy
-More space required for rework and repair, increasing energy
used for heating, cooling and lighting
Waiting Stock-outs, lot processing delays, equipment
downtime, capacity bottlenecks
-Potential material spoilage or component damage causing waste
-Wasted energy from heating, cooling, and lighting during
production downtime
Overproduction Manufacturing items for which there are no
orders
-More raw material consumed in making unnecessary inventory
-Extra products that may spoil (damage) or become obsolete
requiring disposal
-Extra hazardous materials used result in extra emissions, waste
disposal, worker exposure
Motion/Transport Human motions that are unnecessary or
straining, carrying WIP long distances,
transportation
Excess transport of WIP or products
-More energy use for transport
-Emissions from transport
-More space required for WIP movement, increasing lighting,
heating and cooling demand and energy consumption
-More packaging required to protect components during movement
-Damage and spills during transport
-Transportation of hazardous materials requires special packaging
to prevent risks during accidents
Inventory Excess raw material, WIP, or finished goods -More packaging to store WIP
-Waste from deterioration or damage to store WIP
-More materials needed to replace damaged WIP
-More energy used to heat, cool and light inventory space
Over processing More parts, more process steps, or time than
necessary to meet customer needs
-More parts and raw material consumed per unit of production
-Unnecessary processing increases waste, energy use and
emissions
Unused Creativity Lost time, ideas, skills, improvements, and
suggestions from employees
-Fewer suggestions for pollution prevention and waste
minimization opportunities
Sustainable Lean Manufacturing-TPS
Source: EPA “Environmental Guide to Lean” August 2009 Report

16. • 2010
– Insulated facility
– Installed contactors and light switches
– OEE (overall equipment effectiveness “efficiencies”)-Lean manufacturing
• 2011
– New programmable high efficiency boiler
– Replaced 30 x 400w metal halide with T8/T5
• 2012
– Replaced 25 T12 lights with T8
– Replaced 25 x 400w metal halide with T8 and motion sensors
– Replaced 18 x 400w metal halide with T5
– Changes to regrind system – used over 400,000 lbs. of material
• 2013
– Replaced cutting system power supplies with high efficiency power supplies
– Further changes to regrind system, to capture 95% of scrap material produced
Energy Saving Projects

17. Warehouse lights are off most of the time
Lights with sensors Turn off after 10 minutes

18. Recovered energy-diverting regrind from scrap…cost
$3000, material/energy savings of $10,000/yr.
1. old
system
2. old
system
2.new
system
1.new
system

19. Lights w/sensor or illuminated switches
for on/off use

20. Reverse Osmosis System
-Kitchener’s hard water drives up
operational costs for process
equipment such as boilers
-This has a negative effect on
energy consumption due to
constant “blow down”
-Equipment ROI is slow
- Better option than increasing
CO2
- Better option then reducing
boiler life

21. The value of Continuous Improvement with
sustainable manufacturing
1st
reduction
from lean
activities
2nd
reduction
from electrical
& boiler
replacement
3rd
reduction
from electrical
changes & R/O
system

22. • 2009 vs. 2012
• -24 % electricity - $28,000 per year
• -22 % H2O - $4,000 per year
• -17 % NG - $30,000 per year
• CO2 reduction of 22 % per year
• With a 20% increase in production!
– Without changes to energy usage we would have added
$68,000 to our operating cost
• Total 2012 energy savings (including cost avoidance) ….
$130,000
Reductions & Savings

23. Reduce, Substitute or Eliminate
Methodology
While not directly specific to
energy reductions, other little
things add up quickly!

24. Lift trucks- Pick the right equipment

25. Recycle oil-Compressor oil/water filter
System stores oil Filter sent out for recycling

26. • 2009: 102,750
• 2010: 94,454
• 2011: 85,017
• 2012: 83,063
• 2013: 79,800
• On track for a total reduction of 29%
Average Monthly Kwh consumption

27. • Energy
– Lights – approx. 200 old T12 to replace
– Motors – approx. 50 to be exchanged to energy efficient models
– Compressor - VSD
– Enernoc – DemandSMART response program
• Environment
– Reusable/recyclable material programs-Waste EPS regrind
– Launch oxo biodegradable wrap
– Toxic Reduction Act
• Process Equipment
– VOC reduction with new process equipment
Future Sustainability Projects

28. THANKS!
Questions?

29. • http://www.sustainableplant.com/
– Great corporate tools
• http://www.emccanada.org/group_spaces/energy
– Excellence in manufacturing
• http://cme.binaryoak.com/
– Info about TRA Ontario
• http://
www.greenpoweraction.com/business/BusinessCarbonOffsetC
– Calculate your carbon footprint
• https://saveonenergy.ca/Business.aspx
– Financial programs
Resources