1. Page 1Page 1Focused Improvement Page 1
Project Presentation
Project Name: Plant Wide Energy Efficiency
Project Lead: Jacob Stanowski
Presentation Date: July 27th, 2015
Environmental/Energy Pillar
Jefferson North Assembly Plant
Plan Do Check Act
PLAN DO CHECK
SUBJECT TEAM PLANNING

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SUBJECT
Jefferson North Assembly Plant
• 3,000,000 Sq. Foot Facility
• Detroit, MI
• 5,057 Employees
• Produces Jeep Grand Cherokee & Dodge Durango
• 360,456 Units/Year
• $25.7 Million Annual Energy Expense

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SUBJECT Why are we Here?
$-
$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/Type
Loss
Transmission and
Leakage Losses
Not Using Recoverable
Energy Losses
Over Consumption
Non Optimization
Tranformation Losses
Useless Consumption
$-
$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
Useless Consumption of Energy:
$1,180,202 – HVAC
$1,303,406 - Process Electricity
$667,527 - Process Nat. Gas
$164,000 - Compressed Air
$298,290 - Building Electricity
$54,162 - Process Hot Water
$42,156 - Process Chilled Water
Total Annual Loss
= $3,709,743

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SUBJECT Energy Efficiency Project Site Layout
Focus Project:
2016 Plant Wide Energy Efficiency
Body Shop (BIW)
Paint Shop
Assembly (TCF)

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TEAM Team Radar Charts

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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:
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.
All shifts contribute to the useless consumption of energy, but specifically between
shifts, during downtime, and blocked/starved states. Useless consumption of energy is
considered a waste and therefore unethical.
Plan 5W1H Analysis Sheet

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Plan 4M Possible Root Cause
Problem
Current method of data
stratification is insufficient
Not all machines are using
ideal energy saving methods
Material
Machine
Man
Method
HVAC Schedulers are not
functioning correctly
0
0
0 0
0
Clogged HVAC filters minimize
air delivery
0
0
Operators not turning off
machines

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Plan 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 all
Machines are
using ideal
energy saving
methods.
(VFDs, sleep
mode…)
Machines
uselessly
consuming
energy have
not been
modified for
ideal energy
consumption.
Machines
uselessly
consuming
energy are not
identified. Current energy
CD doesn’t allow
to simply &
accurately
identify machines
uselessly
consuming
energy.
Current
CD is
outdated
and lacks
desired
detail.
Current
method of data
stratification is
insufficient
Countermeasure
Expand current energy CD. Complete thorough and detailed energy CD per team area
to allow future projects to accurately, and efficiently attack useless consumption.
Expand current
energy CD.
Complete
thorough and
detailed energy CD
per team area to
allow future
projects to
accurately, and
efficiently attack
useless
consumption.

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Process Equipment: 1629
HVAC Equipment: 235
Dock Doors/Heaters: 44
DO Body Shop (BIW) Data Collection
Processes with notable useless consumption
• B15-SMS - $137,870 Loss
• Metrology - $72,056 Loss
• FRNT-DR-RH - $34,455 Loss

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Process Equipment: 2303
HVAC Equipment: 646
Dock Doors/Heaters: 14
DO Paint Shop Data Collection
Processes with notable useless consumption
• Color Booth #1 - $547,969 Loss
• Color Booth #2 - $490,685 Loss
• Color Booth #3 - $487,769 Loss

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DO Assembly (TCF) Data Collection
Asset List: 1533
HVAC Equipment: 162
Dock Doors/Heaters: 69
Exhaust Fans: 66
Processes with notable useless consumption
• Rolls Equipment - $43,419 Loss
• A2 Team 1 - $38,129 Loss
• Merrill Equipment - $17,256 Loss

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DO Metering & Data Analysis
Preferred TrendUnacceptable Trend

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0
1
2
3
4
5
6
7
2016 YTD 2017 Plant Target
GJ/Unit
KPI Current State vs Target
Total Energy consumption/Vehicle
Natural Gas/vehicle
Electrical Energy/vehicle
6.24 GJ/Unit
CHECK
Energy Consumption Per Vehicle
7.1% Reduction
5.8 GJ/Unit
Estimated Savings
$263,392

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ACT
Column Matrix
Fed from Bus or
panel
MACHINE # of Mach DEVICE ID
Device
Description
Energy Type Process
Additional
Comments
Other
Comments
[T2:T3 ; U2:U3] Panel @ V-3 Rotary Lift Hoist 1 AAA379680 Lift
Compressed
Air &
Electricity
Brake
Reprocess
[U3:U4 ; V3:V4] Panel @ V-3 Rotary Lift Hoist 1 AAA124244 Lift
Compressed
Air &
Electricity
Brake
Reprocess
U3 Bus Plug @ S-6
Repair Area
Exhaust Fan
1 284147 Exhaust Electricity
Brake
Reprocess
[T3:T4 ; U3:U4] Panel @ V-3 Rotary Lift Hoist 1 AAA379681 Lift
Compressed
Air &
Electricity
Brake
Reprocess
[T3:T4 ; U3:U4] Panel @ V-3 Rotary Lift Hoist 1 AAA072087 Lift
Compressed
Air &
Electricity
Brake
Reprocess
[U2:U3 ; V2:V3] Bus Plug @ S-6 Hoist Panel 1 Panel Electricity
Brake
Reprocess
At Column V-3
Bus Plug at
S-6
Repair Area
Exhaust Fan
Hoist Panel
Rotary Lift Hoist
Rotary Lift Hoist
Rotary Lift Hoist
Current
Metering Level

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INTERNSHIP SUMMARY
May – August 2015
• Plant Wide Energy Efficiency Project
• UAW Skilled Trades Supervision
• Plant Wide Air Leak Repair Project
- Kaizen ID 111772. Estimated B/C 254.5%
• Metrology Lab Fire Suppression System
-Kaizen ID 110497. Estimated B/C 208.3%
• Paint Shop Air Shower - ME Compliance
-Kaizen ID 110813. Estimated B/C 500%
• Friction Conveyor Reprogramming
-Kaizen ID 111746 Estimated B/C 53.3%

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INTERNSHIP SUMMARY