Alabama E3 Experience
CLOSE TO OUR CUSTOMERS ON 3 CONTINENTS: A FAST RESPONSE ALWAYS CLOSE AT HAND COMPETENCY CENTERS PRODUCTION CENTERS EUFI – TURKEY - 206 empl. 250 M € EFEC - CHINA - 222 empl. Beynost - FRANCE - 827 empl. 1500 Employees 173 M € 147 M € 53% Tier 1 Sales 100% Automotive SALES, DEVELOPMENT, PRODUCTION & LOGISTICS P R O D U C T I O N EFIS - FRANCE - 105 empl. EFC - USA - 150 empl. 1500 employees worldwide
NORTH AMERICA – ELECTRICFIL CORPORATION 150 ± employees Specialized in Powertrain 250 M € instrumentation (sensors and mechatronic systems) 183 M € 173 M € 147 M € 2006 2011 2012 2015
Plant Floor Recycling Efforts Electricfil Corporation recycles 99% of all production by-products. (examples shown) We also recycle maintenance by-products such as used oil, bulbs, etc. Corrugated Subassembly Packaging Plastic Trays Waste Clippings Runners from Overmold Operations Plant Floor Recycling Station Used Mold Waste Shrink Wrap
Why We Joined the E3 Program Initial Goal of Reducing our Impact on the Environment • Main focus to become landfill free Services were provided at either no charge or at very low cost No-risk with immediate impacts identified Benefits recognized immediately making it easy for Management to support
E3 Assessments and Services Lean Assessment Practical Energy Assessment WRATT – Equipment life cycle costing 2 Kaizen Events • Mixed Model Production at potting • Tool changeover at overmolds Green Specialist Training – Dumpster Dive Assisted in creating Energy and CO 2 Calculators
Initial E3 Assessment Green House Gas Emissions/Carbon Footprint = 1795.6 Metric Tons • Excellent recycling program • Excellent landfill waste reduction efforts Energy Saving Opportunities = $14,946.47 • Lighting = $12,022.51 • Compressed Air = $1510.00 • Motors = $855.36 • Belts = $558.60 Additional Energy Savings Opportunities: • Building Openings • Overhead Doors • Office Equipment • Exit Signs • Thermostat Settings
Lighting Project Existing Light Fixtures • 18 400W Low Bay Metal Halide Fixtures • 40 400W High Bay Metal Halide Fixtures • 33 96” T12 2 -Lamp Fluorescent Fixtures • 2 48” T12 2 -Lamp Fluorescent Fixture • Existing Lighting Level – Ave. 27.57 FC/sq. ft.
Lighting Project Cont. Proposed Light Fixtures • 12 48” T8 6 -Lamp Fluorescent Fixtures w/occupancy sensors • 29 48” T8 8 -Lamp Fluorescent Fixtures • 11 48” T8 8 -Lamp Fluorescent Fixtures w/occupancy sensors • 2 96” T12 2 -Lamp Fluorescent Fixtures – switched • Proposed Lighting Level – Ave. 34.11 FC/sq. ft.
Lighting Project Results Existing Estimated Usage and Cost to Operate • 31.76 Kilo-Watts of Demand • 198,356 Kilo-Watt Hours of Usage Per Year • $15,868 Annual Energy Cost to Operate Proposed Estimated Usage and Cost to Operate • 12.70 Kilo-Watts of Demand • 79,247 Kilo-Watt Hours of Usage Per Year • $6,340 Annual Energy Cost to Operate Proposed Lighting Configuration Savings for EFC… • 19.06 Kilo-Watts of Demand • 119,109 Kilo-Watt Hours of Usage Per Year • $9,528 in Annual Energy Cost to Operate • $950 in Annual HVAC Cost • Combined Utility Cost Savings of Nearly $10,500 Annually!
Compressed Air Assessment No. Size of Leak Cost Savings More Compressed Air Opportunities 1 1/64 $31.00 • Reduce compressed air • Turn off air when not 2 1/32 $122.00 system pressure being used 3 1/32 $122.00 • Use drain traps that • Opportunity to cycle have automatic drains compressors 4 1/32 $122.00 • Remove air lines used • Periodically change 5 1/32 $122.00 for “blow off” filters and do cleaning 6 1/16 $495.50 • Is compressor air intake • Opportunity to use 7 1/16 $495.50 from clean cool location electric motors, not pneumatic motors Total Savings: $1,510.00 Note: Just one 1/16” air leak @ 100 psi cost over $650 @ 10 cents/kwh. Also for every 2 psi reduction in system pressure, there is 1% savings in power. For example, if your shop air is set at 125 psi and 100 psi would work just fine, that would be a savings of 12.5% of the electricity used to run compressors.
Energy Saving Opportunity
Energy Saving Opportunity
Energy Saving Opportunity
Energy Saving Opportunity
E3 Training at Work Reduced landfill bound waste from 40 yards to 2 yards per week Recycle 99% of production scrap waste YTD Monthly Avg General Waste per Employee Avg Headcount per Year 9 160 8 140 7 120 6 100 5 80 4 60 3 2 40 1 20 0 0 2010 2011 2012 2013 2010 2011 2012 2013 2013 Recycling Rebates ≈ $7200 We will make $4975 on our waste by year’s end 2013 Waste Disposal Costs ≈ $2225
Further E3 Impacts Sealed base of plant garage doors and insulated panels to reduce energy loss Installed efficient hand-dryers vs paper towels to reduce waste Reduced energy usage by over 485,000 kWh per year Reduced related CO2 emissions by over 630,000 lbs per year Awarded the 2011 Sustainability in Manufacturing Leadership Award from Alabama Technology Network the Business Council of Alabama Awarded the 2012 Alabama E3 Environment Achievement Award Changed mindset of employees to focus more on sustainability.
THANK YOU Feb. 21 st 2013 – EFC COMMUNICATION MEETING
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