1. Energy Value Stream Mapping
John W. Sheffield, Ph.D.
Industrial EE – July 17, 2013
An application of Value Stream Mapping
based on Lean Manufacturing Principles

2. 2
Forestry Products
(NAICS 321 & 322)
Consumption:
3.3 quad
Energy
expenditures:
$7.6 Billion
US has 25% of
world forestry
production
Chemical
(NAICS 325)
Consumption:
6.24 quad
Energy
expenditures:
$26.9 Billion
25% of US
Industrial energy
consumption
Motor Vehicle
(NAICS 3361)
Consumption:
0.8 quad
Energy
expenditures:
$3.6 Billion
Pioneers of
Value Stream
Mapping
Three Examples of Energy Intensive Industries
Target is energy intensive industries
http://business.edf.org/sites/business.edf.org/files/11206_LCMI-Chemicals-Citations.pdf (2008)
http://www1.eere.energy.gov/manufacturing/resources/forest/pdfs/forest.pdf (1997)
http://www.energystar.gov/ia/business/industry/LBNL-50939.pdf

3. 3
ANALYSIS:
- Record energy consumption data
- Identify energy efficiency potentials
DESIGN:
- Create a future state using design guidelines
- Identify improved energy saving opportunities
REALIZATION:
- Implement future state with energy efficiency measures
- Embed energy efficiency in the core business strategy
Principles of Value Stream Mapping
Energy Value Stream Mapping (EVSM)

4. Energy Value Stream Mapping – Three Steps (MV&A)
4
lmas.berkeley.edu/sites/default/files/posters/saskia-poster.pdf

5. Energy Value Stream Mapping – 3 Phases
5
lmas.berkeley.edu/sites/default/files/posters/saskia-poster.pdf

6. 6
http://app.e2singapore.gov.sg/DATA/0/docs/NEEC%20&%20EENP%20Award%20Ceremony/26%20Klaus%20Erlache_neeconf.pdf
EVSM Service/Tool – Shop floor to Top floor

7. EVSM – How to Identify Energy Intensive Processes
7
- Takt time, which is the cycle time and sets the pace for industrial manufacturing lines
654 Wh 910 Wh 15 Wh
EIpainting = (28 kWe + 123 kWnat gas )x(21.7 sec)x(1)x(1000W/kW)/(3600 sec/h) = 910 Wh

8. Energy Footprint – Pathway Notation
8
http://www1.eere.energy.gov/manufacturing/pdfs/forest_footprint_2012.pdf

9. Forest Products Industry: Total Energy Footprint in U.S.
9
http://www1.eere.energy.gov/manufacturing/pdfs/forest_footprint_2012.pdf

10. Forest Products Industry: Onsite Energy Footprint in U.S.
10
http://www1.eere.energy.gov/manufacturing/pdfs/forest_footprint_2012.pdf

11. Forest Products Industry: Current Situation
11
http://www.ptfbpi.org/Presentations/ReducingElectricalConsumptionOct.%202012.pdf

12. Background on Value Stream Mapping
12
http://www.ptfbpi.org/Presentations/ReducingElectricalConsumptionOct.%202012.pdf

13. Forest Products Industry: Example of EVSM
13
http://www.ptfbpi.org/Presentations/ReducingElectricalConsumptionOct.%202012.pdf

14. Forest Products Industry: Example of EVSM
14
http://www.ptfbpi.org/Presentations/ReducingElectricalConsumptionOct.%202012.pdf

15. Forest Products Industry: Example of EVSM
15
http://www.ptfbpi.org/Presentations/ReducingElectricalConsumptionOct.%202012.pdf

16. Summary
16

17. 17
Energy Value Stream Mapping Elevates Savings
Energy Audit
• Energy Audit
Report (KSI)
ISO50001
SEP
EVSM Tool
(new)
Sustaining
EVSM
(new)
Time
Savings ($ and kWh)

18. 18
Case Studies:
Increasing Industrial Energy Efficiency
Using Energy Value Steam Mapping

19. Case Study #1: Calculation of Energy Intensity
19
Production of a “Front Bumper” made of 5 parts in 4 production steps – the
calculation of energy intensity demonstrates effect of product related approach
Dr. Klaus Erlach - www.energiewertstrom.de

20. Case Study #2: Calculation of Energy Intensity
20
Production of bottle brackets with 40 cells each for a washing machine in
beverage industry – stand-by losses caused by oversizing capacities
Dr. Klaus Erlach - www.energiewertstrom.de

21. Thank You