Reducing Electrical Consumption in the Forest Products Industry Using Lean Thinking ·...

REDUCING ELECTRICAL CONSUMPTION IN THE FOREST PRODUCTS INDUSTRY USING LEAN THINKING

Dr. Henry Quesada-Pineda

Department of Sustainable Biomaterials

Shawn Crawford M.F. Student

Department of Sustainable Biomaterials

Dr. Earl Kline Department of

Sustainable Biomaterials

PTF BPI 11/06/12 King and Prince Beach & Golf Resort St. Simons Island, GA

Overview

Background

Problem

Purpose and Objective

Methods

Results

Conclusions

Background

Energy in the Forest Products Industry

Industrial 26% U.S. electrical 14% Forest Products

Industry < 1% Large majority of the

industry generates onsite energy

Background

Process Improvements Total Productive Maintenance (ideology) Continuous Improvement (ideology) Six Sigma (tool) Lean (ideology) Service Performance Improve quality and reduce cost Minimize the use of assets Track performance improvements Decrease waste

Background

Why Lean?

Lean is customer oriented

Lean thinking is reducing waste by focusing on value-added processes

Value is defined by the customer

“Lean thinking is basically doing more with less." – James Womack

Lean and Energy Toolkit

Energy Treasure Hunts

Value and Energy Value Stream Mapping

Energy Kaizen Events (EPA, 2007)

Background

Process Mapping Business Process Re-engineering Work Flow/Spaghetti Diagram Flow Chart Value Stream Mapping

Background

Problem

Sector Opportunity for Improving Energy Efficiency Cleaner

Fuels Combined Heat and Power

Equipment Retrofit/Replacement

Process Improvement

Research and Development

Cement Medium Low High High Medium Forest Products Medium Low Medium High High

Integrated Steelmaking

Low Medium Low Medium High

Metal Casting Low Low Medium Medium Medium

Metal Finishing Low Medium Medium High Medium

Petroleum Refining

Low High Medium Medium Medium

(EPA, 2007)

Purpose and Objectives

Purpose: Estimate the impact “lean thinking” has on electrical

consumption Objectives 1. Install Energy Management System 2. Identify Product/Value Chain 3. Map Current Process and Energy Consumption

Using Value Stream Mapping (VSM) 4. Create Future State Value Stream Mapping (VSM)

Methods • Energy Management System (EMS) • Installation done by EnerNOC • Test EnerNOC system Install EMS

• Evaluate historical data • Highest volume product Identify

Product/Value Chain

• Flow chart high volume product process steps • Current state VSM of high volume product • Incorporate electrical consumption Current State VSM

• Develop auditing tool • Come up with two-three electrical energy saving

recommendations • VSM implementing electrical savings recommendations

Future State VSM

Results: Install EMS

Provides real time electrical feedback

Rate of 5 minute intervals

Manage energy daily instead of monthly

Results: Install EMS

(Enernoc, 2011)

Results: Identify Value Chain

Results: VSM and Electrical Consumption


Direct Estimation= power rating (PR) for process

Amps X Volts= PR in kWh


Cost allocation technique for electricity Driver is area in units of square feet

1 3 2 4 50 ft

100 ft

5 ft

5 ft

Example: Indirect Consumption


0

200

400

600

800

1000

1200

7/26/2011 9/14/2011 11/3/2011 12/23/2011 2/11/2012 4/1/2012 5/21/2012 7/10/2012 8/29/2012 10/18/2012

kWh

Day

Year Electrical Consumption

Thursday

Friday

Saturday

Sunday

Monday

Tuesday

Wednesday


Before: Fan A and B= 219.7kW Fan A= 93.2kW Lock Valve= 1.5kW Cleaning Pump= 5.8kW Total= 100.5kW

Fan B= 111.9kW Lock Valve= 1.5kW Cleaning Pump= 5.8kW Total= 119.2kW


y = -1.5042x + 978.62 R² = 0.0217 0

200

400

600

800

1000

1200

0 20 40 60

kWh

Sample Per Day

Thursday

Electrical Consumption Per Day

Linear (Electrical Consumption Per Day)

y = -1.0009x + 917.63 R² = 0.0077 0

200

400

600

800

1000

1200

0 20 40 60

kWh

Sample Per Day

Tuesday

Electrical Consumption Per Day

Linear (Electrical Consumption Per Day)


R² = 2E-05

R² = 0.0153

0.00

5.00

10.00

15.00

20.00

25.00

30.00

35.00

40.00

11/3/2011 0:00 12/23/2011 0:00 2/11/2012 0:00 4/1/2012 0:00 5/21/2012 0:00 7/10/2012 0:00 8/29/2012 0:00 10/18/2012 0:00

SqFt

/kW

h

Day

Weekly Production Average Per Daily Electrical Constumption

Monday

Tuesday

Wednesday

Thursday

Friday

Linear (Tuesday)

Linear (Friday)


R² = 0.0011

0

2000

4000

6000

8000

10000

12000

14000

16000

11/3/2011 12/23/2011 2/11/2012 4/1/2012 5/21/2012 7/10/2012 8/29/2012 10/18/2012

Sq. F

t.

Day

Jan.-Sep. Production Rates

Jan.-Sep. Production Rates

Linear ( Jan.-Sep. Production Rates)


1 sec

0.06 days

1.1 sec

1.45 days

2.6 sec

0.07 days

3 sec

0.12 days

Production Control

Weekly Forcast

Veneer Suppliers2 shipments per week

8,807 Panels 1

Head Clippers

T/T= 3.7 sec

C/T= 1.1 sec

C/O= N/A

Time Available= 27000 sec

Travel Time=1.55

Power Rating= 10kW

347Panels 1

Guillotine

T/T=1.4 sec

C/T= 2.6 sec

C/O=N/A

Time Available= 27000 sec

Travel Time=0.53 sec

Power Rating= 7.6 kW

347Panels

1

Whole Challenge Guillotine

T/T=1.1 sec

C/T=1 sec

C/O=N/A

TA=27000 sec

Travel Time=2.2 sec

Power Rating=2kW

756Panels

2

Inspectors

T/T=1.2 sec

C/T=0.8 sec

C/O=N/A

TA=27000

Travel Time= 1 sec

Power Rating=3kW

2,520Veneer Carts

Panels

Core Suppliers3 trucks per week

48 Raw Core

168Panels

Buffer Stock

1

Holzma

T/T=4.8 sec

C/T=1.3 sec

C/O=N/A

TA=27,000 sec

Travel Time=45 sec

Power Rating=20.4kW

1,427Panels

1

North Tech

T/T=5.5 sec

C/T=5 sec

C/O=20 sec

TA=27,000 sec

Travel Time=46 sec

Power Rating=3.9kW

2

Glue Spreader

T/T=3.6 sec

C/T=1.6 sec

C/O=N/A

TA=16,200 sec

Power Rating=1.2kW

240panels

1

Flat Panel Press

T/T=3.6 sec

C/T=1.9 sec

OEE=75.9%

TA=16,200 sec

Travel Time=1.58sec

Power Rating= 44.2kW

275panels

1

Shipping

T/T=2.7 sec

C/T=1.4 sec

C/O=N/A

TA=1,800 sec

Travel Time= 137 sec

Power Rating=0.715kW

491 staging panels

Shipments to Plant 12

Atkins Door Plant

4 shipments/day1,816 panels/day

Daily Automated ScheduleDaily Schedule

540stagingpanels

11.58 hours O.57 hours 0.46 hours 0.99 hours

1.3 sec

0.04 days

5 sec

0.31 days

1.6 sec

O.53 days

1.2 sec

0.05 days

1.4 sec

0.06 days

Processing Time= 18.2 seconds

Production Lead Time= 22.35 hours

0.11 days

4.24 hours 0.42 hours 0.48 hours 0.85 hours

0.29 hours 2.47 hours


2,520Veneer Carts

Panels

2

Glue Spreader

T/T=3.6 sec

C/T=1.6 sec

C/O=N/A

TA=16,200 sec

Power Rating=1.2kW

240panels

1

Flat Panel Press

T/T=3.6 sec

C/T=1.9 sec

OEE=75.9%

TA=16,200 sec

Travel Time=1.58sec

Power Rating= 44.2kW

275panels

1

Shipping

T/T=2.7 sec

C/T=1.4 sec

C/O=N/A

TA=1,800 sec

Travel Time= 137 sec

Power Rating=0.715kW540

stagingpanels

1.6 sec

O.53 days

1.2 sec

0.05 days

1.4 sec

0.06 days

4.24 hours 0.42 hours 0.48 hours

Processing Time= 18.2 seconds

Production Lead Time= 22.35 hours Total Direct Consumption= 541.26kWh/day

Total Indirect Consumption= 17.32 kWh/day


Select SIC code

Instructions: Input your plant area (ft2) 50,000 1. Only fill up the black cells. Do not modify or change any of the formulas Input the number of employees 1232. Select your industry classification (SIC code)3. Indicate your facility size in terms of square footage and number of employees.

Factor ARC code

Item description

Level of compliance

Cost of no compliance (based

on ft2)

Cost of no compliance (based on

employees)

Average payback (years)

Number of implementation

2.1133 ADJUST BURNERS FOR EFFICIENT OPERATION 4 $1,779 $9,852 0.41 8

2.1135 REPAIR FURNACES AND OVEN DOORS SO THAT THEY SEAL EFFICIENTLY 1 $0 $0 0.00 0

2.1231 ESTABLISH BURNER MAINTENANCE SCHEDULE FOR BOILERS 4 $1,252 $7,292 0.79 9

2.1232 KEEP BOILER TUBES CLEAN 4 $19,283 $21,410 0.58 12

2.1233 ANALYZE FLUE GAS FOR PROPER AIR/FUEL RATIO 4 $3,517 $4,420 0.68 84

2.2113 REPAIR OR REPLACE STEAM TRAPS 3 $16,163 $4,111 0.56 8

2.2122 INSTALL / REPAIR INSULATION ON CONDENSATE LINES 4 $28 $321 1.16 12

2.2123 INSULATE FEEDWATER TANK 4 $292 $397 1.04 14

2.2131 INSULATE STEAM / HOT WATER LINES 2 $1,001 $2,763 1.15 76

2.2133 REPAIR LEAKS IN LINES AND VALVES 5 $0 $0

2.2135 REPAIR AND ELIMINATE STEAM LEAKS 1 $11,502 $39,676 1.53 20

2.2153 CLOSE OFF UNNEEDED STEAM LINES 4 $344 $610 0.01 2

Heat containment2.2523

REDUCE INFILTRATION TO REFRIGERATED AREAS; ISOLATE HOT EQUIPMENT FROM REFRIGERATED AREAS 4 $344 $610 0.01 2

2.4111 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS 2 $1,157 $2,277 1.07 340

2.4133 USE MOST EFFICIENT TYPE OF ELECTRIC MOTORS 3 $1,152 $1,780 3.35 337

2.4151 DEVELOP A REPAIR/REPLACE POLICY 4 $653 $1,491 0.88 26

2.4157 ESTABLISH A PREDICTIVE MAINTENANCE PROGRAM 1 $2,606 $3,382 0.19 10

4. Rate every opportunity using the following scale: 5 (No corrective action required), 4 (Evaluation for potential improvement required), 3 (Corrective action required), 2 (Urgent corrective action required), 1 (Inmediate corrective action required). and 0 (Emergency situation)

Furnaces, ovens, and directly fired operations

Boilers

Steam

Motors

Industrial Assessment Center Database (IACD)

Future State VSM

Kaizen event: Incorporate energy audit tool 2-3 energy saving recommendations Implement recommendations Create future state VSM incorporating energy

saving recommendations Evaluate impact through energy management

system (EMS)

Conclusion

Identification of best lean practices to save electrical consumption in a wood products manufacturing environment

Development of an auditing tool based on lean principles to identify energy saving opportunities

For this specific case study, implementing “lean thinking” reduces monthly electrical consumption by X amount of kWh

A developed way of incorporating electrical consumption into a VSM

References

Slide 3: U.S. Energy Information Administration (EIA). Annual Energy Outlook 2011. 2011. Available at <http://www.eia.gov/forecasts/aeo/MT_electric.cfm>. Last Accessed Sep. 26, 2011 Slide5: Womack, J. P. and D. T. Jones. 2003. Lean Thinking: Banish Waste and Create Wealth In Your Corporation. Second edition. Simon & Schusters. New York. Last Accessed Feb. 17, 2012 Slide 5: United States. Environmental Protection Agency. Lean and Energy Toolkit. Washington D.C.: Ross & Associates Environmental Consulting, Ltd., 2007. Last Accessed Feb. 17, 2012 Slide: 7: United States. Environmental Protection Agency. Energy Trends in Selected Manufacturing Sectors: Opportunities and Challenges for Environmentally Preferable Energy Outcomes. Fairfax: ICF International, 2007. Last Accessed Feb. 17, 2012 Slide 11: EnerNOC:Demand Smart. Graphic. EnerNOC, Boston, MA. 2011. Available at <www.enernoc.com>. Last accessed Feb. 7, 2012

Thank You Questions? E-mail: [email protected] Project funded by the Wood Education Research Center (WERC) at the US Department of Agriculture

mailto:[email protected]�

Reducing Electrical Consumption in the Forest Products Industry Using Lean Thinking ·...

Documents

Transcript of Reducing Electrical Consumption in the Forest Products Industry Using Lean Thinking ·...