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BCHI Kaizen-PartiallyReview-up to slide 12.pptx
- 1. BCHI KAIZEN EVENT CutBackonUtilitesexpendituresBest automotive Kaizen- 2020 Chihuahua 1
- 2. Alfredo Cantu Diego Calderon Jorge Ornelas Luis Jurado Liliana Richarte Jorge Heimpel TEAM 2
- 3. Site introduction Brake wear sensor Transfer case Sensor Wheel speed sensor Transmission Speed sensor 660 BCHI 100% Automotive Chihuahua City Population:867 K Total Employees Division Key products Location • We are a Bourns manufacturing site located in America (Mexico). • 100% focused on Automotive components fabrication. • With 660 of the most committed and qualified employees. • As other companies, we use electricity, water and gas to operate and satisfy our customers’ demand. 3
- 4. Greenthinking! Worldwide is well known, that any company must have a strong commitment and responsibility with the environment care In addition to reduce the generated residues, each company must pay attention in the utilities consumption like: Gas Water Electricity 4
- 5. • During the strategic planning (BCHI-FY2020) was defined 5 high performance teams focused on spending administration and reduction • Aligned with environmental commitment and spending reduction strategy our team was focused on utilities consumption reduction. Background 5
- 6. Objective 2020 Reduction of utilities consumption to achieve an spending les than 1.2% vs Sales during 2020 6
- 7. 01 04 Standard weekly follow up meeting- results measurement and activities tracking 03 Each team member will be an sponsor on different actions implementation follow up 02 Define programs or initiatives to reduce the consumption. 01 Identify the main contributors to utilities consumption. Work strategy 7
- 8. Utilities spending is one on the Top 5 spending contributors after payroll. $1,200,000.00 $1,000,000.00 $800,000.00 $600,000.00 $400,000.00 $200,000.00 $- Top spending offenders 2019 (before payroll and depreciation) Spending top offenders 8
- 9. 3% related to Gas consumption 91% Relatedto electricity consumption 6% related to water consumption Utilities Spending Distribution ($US) $580,000 USD 9 $39,000 USD $11,000 USD
- 10. Shut down equipment using emergency stop buttons. Line leader take responsibility to review and ensure shut down equipment and tools. Include visual aids to ensure correct procedure. Program #1: Shut down energy in equipment without normal production. 1 What is the point of inserting this chart if nobody is going to see what it says during the presentation? This visual aid should be translated as shut down when not in use.
- 11. Program #1: Shut down energy in equipment without normal production. Installation and improving ovens software for automatic shut down. 8 Electric Ovens get a software to automatic shutting down after 40 minutes inactivity. 1
- 12. Program #2: Reduce air consumption in manufacturing process. Eliminate continuous venturi system in speed test operations by a electro valve for reduce air consumption. 10 valves changed for an activation only during a part of the cycle. Airflow continuous Airflow controlled Electro valve AFTER BEFORE 1
- 13. Program #3: Install frequency inverters in air cooling system 8 frequency inverters installed in air cooling system Software program adjust according weather season USD$ 18,512 of yearly savings with a ROI of 1 year 13
- 14. Program #3: Install frequency inverters in air cooling system 8 frequency inverters installed in air cooling system Software program adjust according Yearly savings per equipment by USD$2,314 (in total 8 equipments, table is in Mexican pesos) weather season USD$ 18,512 of yearly savings with a ROI of 1 year 14
- 15. Program #4: Follow up to compressed air leaks. Identify and label air leaks. Correct and track through folio number. Report in weekly basis for follow up correction status. +212 Air leaks correction 15
- 16. Program #5: Install new skylight to improve illumination in manufacturing area. 20 skylights substituted. Light intensity improve without energy expense. This change allow to shut down lighting system during part time day. 16
- 17. Program #6: Follow up to equipment substitution. Equipment substitution in order to ensure a high equipment efficiency • Manufacturing area cooling system. • Offices area HVAC (Heating Ventilation Air Conditioning). • Manufacturing area heaters system. • Saving by MXP$405K or USD$20.2K yearly Heating Ventilation Air Conditioning substitution. No investment needed, equipment substitution due to building improvements performed by the leaseholder 17
- 18. 550,000.00 500,000.00 450,000.00 400,000.00 350,000.00 300,000.00 250,000.00 200,000.00 150,000.00 100,000.00 50,000.00 JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC kWh / month Historical Data 2019 - 2020 2019 2020 Results- Kilo Watts per hour/month vs produced pieces per month 18
- 19. Results- Kilo Watts per hour/month vs produced pieces per month - 200,000.00 400,000.00 600,000.00 800,000.00 1,000,000.00 1,200,000.00 Jan Feb Mar Apr May produced Pieces - 2019 Jun Jul Aug Sep produced Pieces- 2020 Oct Nov Dec Produced Pieces per month 2019 vs 2020 CovidImpact Highest amount of production in a month ever 19
- 20. Results-Savings 1.23% 1.20% 1.06% 0.95% 1.00% 1.05% 1.10% 1.15% 1.20% 1.25% Utilites % achieved as of November 2019 (sales USD$48.704M) Target 2020 Utilites % achieved as of November 2020 (sales USD$39.534M) Utilities vs sales cummulative performance as of november 13.8% better than 2019 and 11.7% betterthan planned 20
- 21. Results-Savings 30% of utilities spending reduction 2020 vs 2019 as of November. the mentioned improves and US$50,336.8 from the facility shutdown that happens in April. $120,000.00 $100,000.00 USD$182,202.05 of total $80,000.00 spending reduction, from those: $60,000.00 USD$ 131,865.3 are related to $0.00 $20,000.00 $40,000.00 $140,000.00 $160,000.00 $180,000.00 Spending comparisson 2020 vs 2019 and cummulative Savings as of November 2020 $80,000.00 $200,000.00 $0.00 $10,000.00 $20,000.00 $50,000.00 $40,000.00 $30,000.00 $60,000.00 $70,000.00 Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Utilities spending 2019 Utilities Spending 2020 Cummulative Savings 21
- 22. Project Summary: Many ideas were implemented: Improves as shown in the previous slides are only a few examples of the implemented programs This strategy will continue in the coming years, and the water and gas utilities categories will be improved The constancy in the purpose and the environmental projects need to be a must in our strategic goals, also (as we saw) bringing to the company a financial benefit 22
- 24. THANK YOU! 24
Editor's Notes
- As nouns the difference between spending and expenditure is that spending is an amount that has been, or is planned to be spent while expenditure is (uncountable|countable) act of expending or paying out. Right under BCHI Kaizen event you should write as follows: Cutback on Utilities Expenditures. That is it for this slide.
- It would be a good idea to name your name. Team alone is incomplete. Depending on the mood, you can use nickname for your team, or something like kind of sophisticade as the “ Avant-Garde Team” or think up a name you like, keep it the way it is. It is just a suggestion, ask Angel Perez Ruiz, about the Kaizen Team that went to London as dressed up for the event. Look at the photos as you go past the lobby, where the reception desk is. There are some pictures of other teams that have taken part in these sort of events.
- Instead of total employees say: Headcount. Moreover, the first bullet should be changed for: We are located in Northern Mexico and we are one of Bourns Manufacturing facilities in Central and North-America. Second bullet should be modified as follows: We are 100 % committed to the manufacturing of Automotive Components. Third bullet, We are members of a team of 660 fully committed and highly qualified employees. Four bullet, As many other companies we consume electricity and gas to run our facility and comply with our customer’s demands.
- Define is very ambiguous in this context. What is define? Is it identify? Is it to designate?, is it to delegate responsibility? And I could go on, and on asking questions about the word define. So, I will interpret it the way I see it. Consequently, the first bullet should be changed as follows: During our strategic meeting for 2021, held back in 2020; Five top-performing teams were identified and assigned the task of focusing on cutting back on expenditures. Second bullet, The task of cutting back on expenditure reduction should be aligned with our commitment to protect the environment, so we oriented our efforts on overheads costs related to utilities expenditures.
- The head of this slide is odd and may be confusing for your audience. To clarify that ambiguity, why don’t you change that for, Objective set in 2020. Furthermore, under Objective 2020. It should say, Our objective for this year is to cut back on utilities expenditures down to less than 1.2% of our total sales.
- Contributors to utilities consumption? No, because when you spend you are not contributing, on the contrary you are diminishing. So 01, should be modified as follows: Identify those pieces of equipment that consume the most water, electricity or gas. 02 should be changed as follows, Develop a master plan to cut back on consumption. 03 should be changed as follows, Every team member will sponsor different actions to further cutbacks and will follow up on them. 04 should be changed as follows, Schedule a regular weekly meeting to follow up on and track activities and measure results. Here it is important to indicate how long that meeting will be.
- Please change the title of this slide to : The Biggest Spenders, then under it, change as follows, Top Spending Culprits for 2019 ( before payroll and depreciation) Utilities expenditures are one of the top big spenders right after payroll. In the graph there is a bar for utilities, but no bar for payroll, unless payroll is part of employee welfare.
- How are these percentages computed? 91% out of what? 6% out of what? For example, if you go to a clothing store and you see a blouse that has a price tag of 20 USD, but it also has a discount of 25% percent on its purchase, then we can say that 15 USD is 25% our of 20 USD, so I hope you can understand my explanation of why the blue, gray and green speech bubbles are incomplete.
- First in the other slides you used bullets, here you are using check marks. Be consistent you either use bullets or check marks. This slide should also be modified as follows, Second blue check mark should be modified as follows. Line leaders are accountable for reviewing and making sure that equipment and tools have been shut down after use. Visual aids should be displayed so as to make sure that the shut down process has been carried out appropriately.
- This slide should be modified as follows: Program # 1- Shut down equipment not being used. First check mark, set up and improve on kiln’s/oven’s software to automate the shut down process to 40 minutes of idleness. Moreover, I do not really know what ovens do at BCHI, so depending on this consideriation you opt for one or the other. The difference between an oven and an industrial kiln or furnace is more distinct. There is no specific configuration nor temperature regime ascribed to ovens. ... While kilns and furnaces are used for complex material processes, ovens are more commonly used for bakeout and drying procedures.
- Have someone explain what the Venturi effect is. First blue check mark should be modified as follows, but only in case it pertains to the Ventury Effect. Get rid of continuous Ventury Effects in speed test operations using an electronic valve to reduce air consumption. Second blue check mark should be modified as follows: Ten valves were set up in such a way that they become active during certain phases in the cycle.