Case Studies in Excellent Energy Management Driving ... · Apply lean and six sigma tools to...
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Case Studies in Excellent Energy Management Driving Towards Energy Efficiency Lee Kim Fatt
Transcript of Case Studies in Excellent Energy Management Driving ... · Apply lean and six sigma tools to...
Case Studies in Excellent Energy Management Driving Towards Energy Efficiency Lee Kim Fatt
Overview
GLOBALFOUNDRIES Confidential 2
About GLOBALFOUNDRIES
Energy policy and roadmap toward
energy efficiency
Energy improvement projects
1
2
3
4 Sustained energy performance
GLOBALFOUNDRIES Confidential 3
About GLOBALFOUNDRIES 1
Energy policy and roadmap toward
energy efficiency
Energy improvement project
2
3
4 Sustained energy performance
About GLOBALFOUNDRIES
• GLOBALFOUNDRIES is the world’s first full-service semiconductor
foundry with a truly global footprint.
• Launched in March 2009, GLOBALFOUNDRIES has quickly
achieved scale as the second largest foundry in the world,
providing a unique combination of advanced technology and
manufacturing to more than 160 customers.
• Our manufacturing centers in Germany, the United States and
Singapore deliver advanced technologies to market in high volume
and mature yield faster than any other foundry in the world, and
offer an outstanding legacy of foundry operational and customer
service excellence.
GLOBALFOUNDRIES Confidential 4
GLOBALFOUNDRIES Confidential 5
Energy improvement project 3
4 Sustained energy performance
About GLOBALFOUNDRIES 1
Energy policy and roadmap toward
energy efficiency 2
Electricity Tariff Trend
Observations
▪ Singapore has one
of the highest
electricity tariff in
the world
▪ Total Energy Costs
in Singapore has
increased 9-18% on
a per annum basis
in last 4 years
▪ Reduction in overall
energy cost is one
of the main focus
areas going forward
0.00
5.00
10.00
15.00
20.00
25.00
30.00
2009 2010 2011 2012
Average tariff rate
source: Singapore Power
¢/kWh. Average High Tension supplies
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Electricity Consumption
(42%) Fab
19%
Sub fab
23%
(3%)
(5%) MUA+
VLF
Exhaust
PCW (4%)
(12%)
(28%) Chilled Water System
(6%) UPW
Gas+
lighting
Manufacturing
Equipment
Overall
Category
Fab Tools, Chilled Water System & Gas equipment
- Energy-intensive components
- High potential of waste energy/heat
recovery/reduce
Energy Profile
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Energy Efficiency (EE) Program in 3 Dimensions
▪ Cultivate change agents through systematic
training, project practice and expert instruction
▪ Develop right understanding of energy cost
▪ Increase sense of urgency and infuse
continuous improvement mindset
Mindsets, behaviors and capabilities
Management infrastructure
▪ Create end-to-end
view of energy value
chain
▪ Leverage theoretical
limit analysis
▪ Apply lean and six
sigma tools to
eliminate waste
Technical system
▪ Install energy
performance
management system
▪ Enhance cross-
functional/unit
collaboration
▪ Set up energy efficiency
continuous improvement
mechanism
▪ Define clear energy
management governance
and organization
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5 + 1 R Utilities Cost Reduction Approach
Re-Use Reclaim Reduce Re-source Re-Think Re-Contract
2010
2011
2012
2013 2014
Wastage
Minimization
System
Optimization
Energy
Efficient
Upgrade
- Lighting reduction
- Increase office
temperature
- Shut-off non essential
lighting
- Reduce contract cost
- Tool exhaust
optimization
- PCW flow
optimization
- CHW flow
optimization
- EE Chilled Water System
Retrofit
- LED lightings Upgrade
- EE vacuum pump
upgrade
- EE N2 Generation Plant
1.0 %
Reduction
2.0 %
Reduction
5.0 %
Reduction
7.0 %
Reduction
Road Map towards Energy Efficient
9
GLOBALFOUNDRIES Confidential 10
4 Sustained energy performance
About GLOBALFOUNDRIES 1
Energy policy and roadmap toward
energy efficiency 2
Energy improvement projects 3
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Energy Improvement Projects
• Exhaust Recycling
Energy Improvement Projects
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• Reduce Exhaust to “Just Enough” to the tool requirement
Energy Improvement Projects
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Cleanroom
18 Pa
Current
Cleanroom
10 Pa
Proposal
• Reduce Clean Room Pressure
Energy Improvement Projects
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Heating, Ventilating & Air-Conditioning System (HVAC) is one of the major energy-
consuming component in industrial & commercial building. In a typical wafer fab,
about 20-30% of total electricity is consumed by HVAC System.
Improve system efficiency to 0.65 kW/RT
0.65 kW/RT 1.00 kW/RT
• EE Chilled Water System Retrofit
Energy Improvement Projects
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Low Q (Flow)
High ∆ T (Temperature)
Low ∆ P (Pressure)
Variable Speed
Drive (VSD)
DUPLEX Chiller (Dual Compressor
in Series)
Hermetic Compressor
- Reduce friction losses
- Reduce transmission losses
• EE Chilled Water System Retrofit
Energy Improvement Projects
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Conventional
Fluorescent Light
> 60%
Reduction
• Upgrade Conventional Fluorescent Lighting to LED
Energy Improvement Projects
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GLOBALFOUNDRIES Confidential 18
About GLOBALFOUNDRIES 1
Company energy policy and roadmap
toward energy efficiency 2
Energy improvement project 3
4 Sustained energy performance
Sustained Energy Performance
1. Energetic and passionate energy management team
2. Employees involvement and generate new ideas
3. Rewards and recognition
4. Joint effort with universities
GLOBALFOUNDRIES Confidential 19
Hydrocarbon based energy source
Non-hydrocarbon based energy source,
Clean energy source,
Renewable energy source
Source from http://commons.wikimedia.org/wiki/
Types of Energy Source in the World
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Electricity Consumed
α
NOx, CO2 Emission Picture source: Randomly from world wide web
It’s not just about cost saving, $........ Environmental Protection
Why go towards EE & Energy Conservation?
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© 2013 GLOBALFOUNDRIES Inc. All rights reserved.
Thank you
