"Lean and Green" Energy Savings at Smithfield Manufacturing

356 views

Published on

Published in: Business, Technology
0 Comments
0 Likes
Statistics
Notes
  • Be the first to comment

  • Be the first to like this

No Downloads
Views
Total views
356
On SlideShare
0
From Embeds
0
Number of Embeds
138
Actions
Shares
0
Downloads
8
Comments
0
Likes
0
Embeds 0
No embeds

No notes for slide

"Lean and Green" Energy Savings at Smithfield Manufacturing

  1. 1. “Lean and Green” Energy Savings at Smithfield Manufacturing Ron Smithfield, President Smithfield Enterprises, Inc. 237 Kraft Street Clarksville, TN June 13, 2013
  2. 2. Where is Smithfield Manufacturing?
  3. 3. Commercial & Military Nationwide
  4. 4. 60 Years in Clarksville • 1952 Founded by Basil & Sue Smithfield • 1988 Tennessee’s “Factory of the 90’s” • 1989 started “Lean Manufacturing” • 1999 Tornado destroyed half of plant • 2000 BBB Torch Award for tornado recovery • 2005, 2008 & 2011 ISO9001:2008 registered • 2012 Green Certified
  5. 5. What do Lean and Green have in common?
  6. 6. What do Lean and Green Certification have in common? 1. Inputs (“Aspects”)
  7. 7. What do Lean and Green Certification have in common? 1. Inputs (“Aspects”) 2. Outputs (“Impacts”)
  8. 8. What do Lean and Green Certification have in common? 1. Inputs (“Aspects”) 2. Outputs (“Impacts”) 3. Goal: Minimize Waste (“3 R’s”)
  9. 9. “Lean Thinking” • Lean = 1. right things 2. right place 3. right time 4. right quantity 5. minimize waste 6. Continuous improvement
  10. 10. Raw material to finished part
  11. 11. Machining component for Electronic Wheel Balancer
  12. 12. Environmental Policy 1. Smithfield Manufacturing, Inc. will institute sustainable systems and measures to reduce waste & pollution .
  13. 13. Environmental Policy 2. We will involve all of our team members in being environmentally responsible while providing quality components and services to our customers.
  14. 14. SMI Goals within 12 months (July 2011) 1. Reduce Electricity $ by 10% 2. Recycle more Metal Scrap $ by 20% 3. Reduce Oil &Coolant Disposal $ by 20% 4. Reduce Packaging $ by 10% 5. Reduce Transportation $ by 10%
  15. 15. Goal #1: Reduce Electricity $ by 10% 1. TVA audit – Replace 480 watt metal halide lights with 277 watt T-5 electronic fixtures- save 40%. 2. Set back thermostats for heating and cooling. 3. Turn off unused lights. Automatic lights for safety. Motion detecting switches.
  16. 16. Before Lighting Project
  17. 17. More efficient lighting + 40% savings
  18. 18. Before
  19. 19. After
  20. 20. Lighting Project • Pathway Lending, Nashville • Application on line • Terms: 5 years at 3% interest • TVA study justified payback period < 5 years • Installed by our maintence staff
  21. 21. Saving electricity after hours
  22. 22. Strips on overhead doors
  23. 23. Green Certification Ribbon Cutting May 2012
  24. 24. 2012 Best Small Business Green Program
  25. 25. Since Green Certification? 1. New high efficiency Air Compressor for $700/mo savings 2. Replaced 20 yr old Heat Pump for office 3. Installed “Air Pears” to de-stratify heat 4. Replaced 2 old HVAC units with high efficiency American Standard units
  26. 26. Compressed Air = Energy “Hog” Before: • 50 hp constant-running Air Compressor • “Off-load” still used 60% power After: • 25 hp Variable Speed Air Compressor • 40% of electricity (saving $700/month) • Payback originally estimated at 4.5 years • Actual payback about 3 years
  27. 27. Air Compressor Estimated Savings 1st in Tennessee for Pathway Lending
  28. 28. Variable Speed Air Compressor QGV Variable Speed Lubricated Rotary Screw Compressor Performance 0.0 20.0 40.0 60.0 80.0 100.0 120.0 0 20 40 60 80 100 120 Percent Capacity Percent InputPower % power input vs % capacity Ideal Compressor
  29. 29. Before : 50 H.P. Screw Air Compressor
  30. 30. Variable Speed Air Compressor
  31. 31. Smart Air Compressor at only 8.6 h.p.
  32. 32. Air Drier assures clean dry air
  33. 33. 38% savings Variable speed AC
  34. 34. April 2013 vs April 2012
  35. 35. 2010 – 2013 Electricity Costs Year Electric Costs Demand costs Demand % Comments 2010 $53,988 $11,698 22 % Baseline 2011 $51,675 $9,094 18 % Started Green Certification 2012 $46,311 $7,587 16 % Hottest summer 28 yr 2013 (Jan- May) $13,856 $819 6 % Before cooling season
  36. 36. Heat Stratification (before) • 10 -16 degree difference ceiling to floor
  37. 37. “Air Pear” Thermal Equalizer • Can project a column of air 50 ft. Model 25 110 v. or 240 v.
  38. 38. “Air Pear” Thermal Equalizer (after) • 1 – 2 degrees difference ceiling to floor Our Results: Team Members more comfortable & save heating cost
  39. 39. Approved for 5 years at 3% interest. Savings greater than the monthly payment Payback now estimated at 4 years.
  40. 40. • Tennessee companies only • Energy savings evidence required • Projects: lighting, HVAC, air compressors & solar • Payback of 5 years or less at low (2%) rates • Loan applications at www.pathwaylending.org
  41. 41. 1. Saving $700/month with “Smart” Air Compressor 2. Saving $300/month with high efficiency lighting 3. Reduced coolant disposal by 40% 4. Reusing surplus pallets from local companies 5. Developed water saving “Meter Yoke Vise” 6. Installed “Air Pears” to de-stratify heat 7. New high efficiency HVAC units in plant Smithfield Manufacturing
  42. 42. Energy efficiency in the office 1. Set-back thermostats 2. Replace T-12 with T-8 bulbs or T-5 fixtures 3. “Sleep mode” for computers during day 4. Turn off copiers, computers & power strips 5. Motion detectors to turn off lights 6. Double-sided printing 7. Reuse scrap paper on opposite side 8. Buy USA made products locally (if possible)
  43. 43. Lessons Learned 1. Have TVA or CDE conduct an Energy Audit 2. Apply for rebates before starting work 3. Get Team Members involved in setting Goals 4. Make Goals simple but achievable 5. Post Results very month 6. Compressed Air is expensive! 7. Use Pathway Lending to finance energy projects 8. Customers appreciate Green effort
  44. 44. Reduced Break-even = “Sustainability”
  45. 45. “The worst form of WASTE is saying you can’t improve.” James Womack, Lean Consultant Question?
  46. 46. The End Contact: Ron Smithfield, President Smithfield Enterprises, Inc. 237 Kraft Street Clarksville, TN 37040-3003 (cell) 931-624-5132, (Office) 931-552-4327, (FAX) 931-648-4460 www.smithfieldmfg.com Email: RonSmithfield@aol.com

×