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Lean Energy
- 1. LEAN ENERGY Dr. JohanWollin
- 2. Dr. Johan Wollin Department,Name, Document name, Security class Date2 • Global Director Energy Management • Previously worked at Toyota as Toyota Production System / Lean expert • PhD in Mechanical Engineering from Coventry University, UK • Swedish national
- 3. Volvo Construction Equipment Department,Name, Document name, Security class Date3 Part of Volvo Group 14000 Employees €7 Billion company 190 Markets
- 4. Our brands Department, Name,Document name, Security class Date4 Leading premium brand offering a wide range of construction equipment Leading Chinese construction brand (joint venture)
- 5. Industrial footprint –15 plants Department, Name, Document name, Security class Date5
- 6. Department, Name, Documentname, Security class Date6 TO BECOME THE WORLD LEADER IN SUSTAINABLE TRANSPORT SOLUTIONS Building the world we want to live in A sustainable future for everyone
- 7. Department, Name, Documentname, Security class Date7 Increased machine fuel efficiency Host the Construction Climate Challenge Standardization leadership Production site energy efficiency Advanced technology development Eco-operator training & site optimization 1 2 3 4 5 6 Working with WWF
- 8. Starting at thebase – Energy Conservation (never ending...) Department, Name, Document name, Security class Date8 Renewable Energy Energy Efficiency Energy Conservation
- 9. What does itmean? Department, Name, Document name, Security class Date9 • Turn off non-essencial equipment • Turn on non-essencial equipment later and turn it off earlier • Use existing equipment in a smarter way • Use right sized equipment • Invest in more energy efficient equipment • Invest in energy recovery • Buy green electricity • Switch energy sources away from CO2 emitting ones • Investigate own energy production Energy Conservation Energy Efficiency Renewable Energy
- 10. A culture buildingstrategy Department, Name, Document name, Security class Date10 Low cost Self funded Culture and behavior Why start with idle electricity? Reduce cost for future improvements Idle Electricity Production Energy Renewable Energy
- 11. Project management usingA3 Department, Name, Document name, Security class Date11
- 12. How to measuresuccess? Department, Name, Document name, Security class Date12 Target: Reduce relative idle electricity to less than 15% before end of 2015 Production electricity (kWh’s during 10 production hours) Idle electricity (kWh’s during 10 idle hours)Relative idle electricity % = Clear KPI with stretched target Able to compare plants
- 13. Pareto thinking tofocus & prioritize Department, Name, Document name, Security class Date13 Energy intensity of 0.54% Energy use per type • Electricity represents > 50 % Electricity use per plant • Seven plants capture >75 %
- 14. Total electricity use Department,Name, Document name, Security class Date14 2012 2013 2014 2015 2016 2017 2018 0 500,000 1,000,000 1,500,000 2,000,000 2,500,000 3,000,000 3,500,000 4,000,000 KWh/week Actual 12-month rolling 2019 2020 2021 2022 2023 2024 2025
- 15. Idle electricity use48% lower Department, Name, Document name, Security class Date15
- 16. Waste elimination withoutinvestments using Lean thinking Department, Name, Document name, Security class Date16 • Waste hunts – Night walks with management – Reinforced end of shift routines – Energy treasure hunts (2-3 days workshops) • Timers, motion sensors & twilight sensors • Building control system for light and ventilation
- 17. Results – Beforeand After Department, Name, Document name, Security class Date17 June w26 2015 (before) November w48 2015 (after) 0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 kWh 0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 kWh Mon Tue Wed Thur Fri Sat Sun Mon
- 18. Step 2 –Energy Efficiency Department, Name, Document name, Security class Date18 Renewable Energy Energy Efficiency Energy Conservation
- 19. We have saved50 GWh’s of energy Department, Name, Document name, Security class Date19
- 20. Energy cost /unit reduced with 27% Department, Name, Document name, Security class Date20 10 000 20 000 30 000 40 000 50 000 60 000 70 000 80 000 90 000 100 000 0 500 1000 1500 2000 2500 3000 2014 2015 2016 2017 2018 (Units) (SEK/ unit) Energy cost / produced unit Energy cost/unit Produced units
- 21. We have implementedat total of 450 energy saving actions Department, Name, Document name, Security class Date21 0 20 40 60 80 100 120 140 2014 2015 2016 2017 2018 Number of implemented energy savings 0 5 10 15 2014 2015 2016 2017 2018 Energy savings in GWh
- 22. Step 3 –Renewable Energy Department, Name, Document name, Security class Date22 Renewable Energy Energy Efficiency Energy Conservation
- 23. Renewable Energy actions Department,Name, Document name, Security class Date23 We use green electricity in markets where available Braås plant in Sweden 100% renewable since January 2014 Selected investments in renewable energy production (India solar farm) Long term projection and target established on each site to drive right investment decisions
- 24. Renewable Energy roadmap Department, Name, Document name, Security class Date24 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 2016 2020 2024 2028 2032 2036 2040 2044 2048 Renewable% Projected OMT Challenge Actual Status: X
- 25. Lean energy thinkingways Department, Name, Document name, Security class Date25 Level 1 Water is always on Water tap in your kitchen at home Level 2 Water is on when you are at home Level 3 Water is on when you are at home and awake Level 4 Water is on when you are in the kitchen Level 5 Water is on when you need water Level 6 Water is on when you need it and only to the extent needed Usage Our vision is to reach level 1
- 26. Power vs Time Department,Name, Document name, Security class Date26 Time Power 1 kW 1h 1.5 kW 0.5h1h 0.75 kW Original Improvement 1 Improvement 2
- 27. Pasta cooking exercise Department,Name, Document name, Security class Date27
- 28. The steps forcooking pasta Department, Name, Document name, Security class Date28 Time Prep Boil Cook Clean A. Hobs C. Celing lights B. Extraction fan with lights D. Kitchen Heating
- 29. Energy use whilstcooking pasta Department, Name, Document name, Security class Date29 Time 2 min 3 min 9 min 1 min D Heating C Lights A Hobs B Fan 1 min 1,5 min 3 min 1 min A. Hobs C. Celing lights B. Extraction fan with lightsD. Kitchen Heating
- 30. Non-Energy Benefits (NEB) Department,Name, Document name, Security class Date30 MOTIVATION COSTQUALITY PRODUCTIVITY / RELIABILITY SAFETY Less working on height with LED lights due to their longer life expectancy Optimized machining to reduce time and same time improve surface quality Detailed understanding of the production process enable optimization of cycle times Running oil separator only when machining increase filter chance frequency Celebrating achievements together and motivate for continuous improvements in other areas
- 31. Non-Energy Benefits (NEB) Department,Name, Document name, Security class Date31 NEB = 2.5 x Energy cost reduction Hall et. al. 2003
- 32. Why working withEnergy Management? Department, Name, Document name, Security class Date32 Reduce cost Environmental care Non-energy benefits Train continuous improvements
- 33. Summary of results Department,Name, Document name, Security class Date33 • Idle electricity use reduced by 48% • Lower energy bills • Total energy savings of 50 GWh • Many Non-Energy Benefits • Energy cost per unit reduced by 27% • Total 100 MSEK in cost savings over 5 years
- 34. Learning Department, Name, Documentname, Security class Date34 • Just do it! • Push responsibility out on the shop floor and harness ideas • Communicate in an easy to understand format (A3) • Get sense of urgency by external driver (WWF) • Don’t invest until low cost improvements have been attempted • Share success stories and best practice widely
- 35. Introduction to IndustrialEnergy Efficiency Department, Name, Document name, Security class Date35 Patrik Thollander, Magnus Karlsson, Patrik Rohdin, Johan Wollin, Jakob Rosenqvist Paperback ISBN: 9780128172476 Elsevier Science 30th January 2020 https://www.elsevier.com/books/introduction -to-industrial-energy- efficiency/thollander/978-0-12-817247-6
- 36. Department, Name, Documentname, Security class Date36 Questions? johan.wollin@volvo.com