3. Why Are We Here?
JNAP Total Perimeter Costs
$395.8M
3
6.5% of Perimeter Costs
4. 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/Type
Loss
Transmission and
Leakage Losses
Not Using Recoverable
Energy 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
5. What is the Goal
• Reduction in Energy Consumption
• Target is 5.98 GJ/Unit by 2020
Source
2009
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
Gas
12.46 9.02 5.90 4.81 5.07 4.86 4.38
Total
Energy
18.32 13.10 8.28 6.92 6.95 6.59 6.09
* All numbers are in GJ/Unit 5
6. 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
7. WCM Tools (4M)
Problem
Current method of data
stratification is insufficient
Not all machines are using
ideal energy saving methods
Material
MachineMan
Method
HVAC Schedulers not
functions
Clogged HVAC filters minimize
air delivery
Operators not turning off their
machines
7
8. 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 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.
Expand current
energy CD.
Complete
thorough and
detailed energy CD
per team area to
allow future
projects to
accurately, and
efficiently attack
useless
consumption.
Countermeasure
Expand 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
9. 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
10. 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
• HVAC Equipment: 646
• Dock Doors/Heaters: 14
– Pieces of Equipment Total in TCF:
• Process Equipment: 1533
• HVAC Equipment: 162
• Dock Doors/Heaters: 69
10
11. Tracking Back to the Bus Level
11
Column Matrix Fed from Bus or panel MACHINE # of Mach DEVICE ID Device Description Energy Type Process
Additional
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 000284147 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
A2
Substation
A2B-2 Bus
Plug at S-6
Repair Area
Exhaust Fan
Hoist Panel
Rotary Lift Hoist
Rotary Lift Hoist
Rotary Lift Hoist
Feeder
Breaker
Metering
12. Kaizens
• Kaizen IDs:
– 110813 – Air Showers to Paint Booths
– 110816 – Air Showers to Paint Booths
– 110818 – Air Showers to Paint Booths
– 110821 – Air Showers to Paint Booths
– 111742 – Air Leaks in Paint
– 111859 – Stair Safety Hazard
12
13. 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
14. 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
15. 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
I have been working with the Energy Pillar, which is a subset of the environmental pillar this summer. The energy portion of the pillar is lead by Rich Hutchins.
Energy is the fourth largest cost in the plant, and is 6.5% of the perimeter costs.
Useless Consumption is the top loss in the energy pillar. This is a List of where the most useless consumption happens. Useless consumption makes up almost $4,000,000 in costs to the plant.
The goal is to reduce plant energy consumption per vehicle to 5.98 GJ/Unit by 2020.
This is the 5W1H that I came up with. The Problem Description is that…
I found that the most likely culprits are that not all machines are using ideal energy saving method, and that the current method of data stratification is insufficient. So I moved on to our 5 Why.
With the 5 why I found that we needed to expand the current energy CD. The CD needs to be thorough and detailed so that we can more accurately attack useless consumption.
The first thing that I did was collected asset data from each area of the plant. I looked specifically at equipment that consumed Compressed Air, Electricity, and Natural Gas. Then I took some measurements to better understand what we are attacking, and why we are attacking it.
As a result I found that Body had about 1629 pieces of process equipment, paint had 2303, and assembly had 1533.
Since we have data at the bus level for equipment. I needed to follow the equipment back to the bus level. Some of the equipment said where it fed from. Other pieces did not. Finding this will help assign heavy usage areas that can be attacked to reduce heavy useless consumption of energy.
While working on the main project, I found several other problems. I attacked these with the help of the Energy Pillar Intern and Environmental Pillar SVR.
The first problem we attacked was the Air Showers to Color Booth 1, 2, and 3. These booths were not working properly, and we found that the issue was that no body would reset the machines after pressing the E-Stop. We placed these signs by the showers to help influence people to restart the showers. These showers keep foreign materials from the car during the paint process, and without them working there is a huge risk of foreign contamination. This is only a short term fix however. The long term fix would be to reprogram the showers so they work properly.
In this kaizen I found that throughout all of the centers there were many air leaks, but paint was especially bad. So, I got in touch with Andy Whitsitt, the Environmental lead and assisted his SVR with the locations of the air leaks. She then quantified them and put them into the catalog, and they are being attacked when the skilled trades can.
