Workshop G Energy Savings Champions – Best Practices & Case Studies in Energy Reduction & Energy Efficiency in Award-Winning Industrial Corporations Tuesday, February 18, 2020 1:45 p.m. to 3 p.m.
Biographical Information Mark A. Brady, Plant Engineer, Bridgestone APM Company P.O. Box 450, 235 Commerce Way, Upper Sandusky, Ohio 43351-0450 419-731-2241 Fax 419-294-3147 mabrady@bapm.Com Mark started his industrial career in 1978 with Guardian Automotive Glass in Upper Sandusky Ohio. He spent the majority of his time there in the maintenance department taking on various responsibilities. Plant power was one, including the operation of the primary sub-station that fed the plant. He always involved himself in special projects involving modernization, productivity and cost effectiveness. After fifteen years he decided to change automotive materials and started working with rubber at Bridgestone Auto Parts Manufacturing. Bridgestone APM has been his home for the last twenty-seven years, first in maintenance and the last ten years in the building aspect of things. His current responsibilities as plant engineer include the building, plant air, power, ventilation, lighting and equipment installation. All of these areas have lent themselves to energy saving projects in recent years thanks largely to the help and encouragement of AEP Ohio. The Grid-Smart program and CEI groups have helped greatly with ideas and direction on what can be done and how to get them implemented. As a corporation, we appreciate their help and experience for sustainability and progress in our goal to be more resource conscience in our production facilities. Andrew K. McCabe, Manager-Business Programs, AEP Ohio 700 Morrison Rd, Gahanna OH 43230 614-883-7876 akmccabe@aep.com Andy started his energy career with AEP in New York City in 1976 as a station design engineer. In 1993, Andy participated in the start-up of AEG Power Systems, Inc. in Charleroi, PA to manufacture high-voltage circuit breakers. In 1997, AEG was purchased by GEC Alsthom with Andy become US T&D Commercial Director. In 2018, Andy returned to AEP in T&D asset management. In 2010, Andy was promoted to Manager of Business programs for Energy Efficiency and Peak Demand reduction. In 2019 Andy was promoted to Portfolio manager for Energy Efficiency and Peak Demand reduction. Andy is a graduate of Polytechnic Institute of Brooklyn with a B.S. in Electrical Engineering and received an MS is Electrical Engineering from Polytechnic Institute of New York. Andy is a CEM, CEA and REA. Andy is a Life member of IEEE.
Biographical Information Gary Hendrickson, AEP Ohio CEI Team 445 Hutchinson Ave. Suite 300, Columbus, OH 43235 740-974-6587 – Cell Gary.hendrickson@clearesult.com Gary Hendrickson is an engineering manager who has been formally trained in TQM, Strategic Planning, Project Management, Product Development, Lean & Six Sigma methodologies with over 15 years of proven experience in facilitating business transformation projects that have delivered improvements in product quality, process efficiency and supplier performance. His additional strengths are data analysis, drive to achieve goals, ability to quickly learn new disciplines, motivating others to eliminate waste/reduce cost and improve customer service levels. His specialties include: Total Quality Management • TPM • Project Management • Lean Six Sigma • Strategic Planning • Supply Chain Strategies • Supplier Management/Development • 5S Visual Management • Statistical Process Control • FEMA • Work Force Development • Value Stream Mapping • ISO9000 • TS16949 • Documentation management & vintage control • Re-engineering Techniques • New Product Introduction • Kaizen • CAPA (8-Disciplines) • Balanced Score Card Since November 2012, Gary has served as SEM Program Manager for CLEAResults. Through a series of SEM workshops and providing individual coaching, the client learns to apply the principles of Strategic Energy Management to reduce their energy intensity by 5% year-over-year. • Coached and site facilitation of 42 energy teams to yield 103.5 GWh (10%) of savings over a 3-year period. • 18% of the CEI clients were recognized by local utilities and hospital associations for their superior energy reduction performance. • Introduced advanced project management techniques to maintain team focus and performance • Taught and coached ADKAR Change Management model to support sustainability • After coaching the client on how to build a strong energy management foundation, two SEM program graduates go on to become ISO 50001 certified. Prior to his experience with CLEAResults, Gary was the Supplier Quality Improvement Manager At Cummins Inc. managing a Supplier Quality Team of 5 engineers and 10 technicians for current and NPI product. Work with the Plant Leadership team to develop long term Quality improvement plans to continuously improve our supply base. • Using supplier quality improvement technics my team reduced the defects from a critical supplier by 85% • Ensure effective deployment of APQP/PPAP processes for components within NPI programs resulting in the prevention of 6 major quality spills. • Lead Supplier Improvement Process (SIP) to achieve PPM targets for selected suppliers resulting in a 54% reduction in 7 months. • By negotiating increased involvement from other Cummins’ locations and driving improvements in supplier response to close CAPA s; we reduced the time to close a quality issues by 37%. More biographical information can be found at: https://www.linkedin.com/in/glhendrickson/
Networked LED Lighting
132 Albeo LED Fixtures 110 6 Bulb T5 Fixtures Lumen Approx. 36,000 Lumen Approx. 25,800 Watts @ 221 /Fixture Watts @ 351 / Fixture 49 Units on Motions 12 Units on Motions Watts @ 80% / 177 Lumen 80% / 28,800 Optics 120° / 5000K GE Daintree Controls Weekend Schedules Daylight Harvesting Motion Detectors Previous Lighting Programmed Lighting
T5 HO 6 Bulb GE Albeo ABV3
Former Former Improved Improved Luminaire Description 6 Lamp T5 HO GE ABV3 LED Per Luminaire Wattage 351 177 @ 80 % System Watt 36,610 14,603 Annual Kilo-Watt Hours 338,224 127,918 Annual Energy Costs $32,131 $12,152 Project Cost With Additional Wiring $98,000 AEP Ohio Incentives Program Rebate $27,000 Simple Payback In Years 3.5 Five Year Cash Flow $29,968
Kenworth Truck Company Manufacturers’ Education Council February 19, 2019 Curtis Crego 13 Chillicothe Plant
Chillicothe Plant
Kenworth Truck Factories Montreal, CN Renton, WA Chillicothe, OH Mexicali, MX Chillicothe Plant
Facilities Space: 530,000 Sq Ft Site Size: 119 Acres Construction Start Date: 1973 1st Truck Off Line: March 1974 Build Rate: 170 Trucks Per Day Build Rate Capability: 170 Trucks Per Day 2,350Employees Chillicothe Plant
T680 T880 W990 T880S Chillicothe Plant
Corporate Focus Energy and the Environment • Focus on Energy and the Environment • Energy usage changes are recorded as part of all capital projects • 36% Reduction in GHG emissions over the past six years • Direct Fuel Usage (Natural Gas) • Electrical Energy 18 Chillicothe Plant
Focus on Energy Kenworth Chillicothe • Kenworth Expectations • Goal • 5% reduction in power consumption, per truck, Y ‐ o ‐ Y for five years 2014 ‐ 2019 • Baseline • 1,500 kWh/truck • Results to Date • 1,000 kWh/truck • Savings per year • 21,250,000 kWh/year savings 19 Chillicothe Plant
AEP & Kenworth Partnership • AEP provides resources and incentives for its customers • Their investment in the customer supports PACCAR’s (Kenworth’s) Energy & Environmental goals • Multiple programs available 20 Chillicothe Plant
Actions Taken • Replacement of a High ‐ Air Multipliers Pressure air compressor with air multipliers Occupancy Sensors (boosters) • Reduced compressed air setpoint within the factory • Installation of 120+ Compressed Air Setpoint occupancy sensors in offices and conference rooms 21 Chillicothe Plant
Actions Taken • Implemented a BAS to Building Automation System control OCC v. UNOCC of HVAC equipment • Installation of new compressed air equipment Compressed Air System • Air Compressor sequencing 22 Chillicothe Plant
Actions Taken • Installation of five new LED Lighting New RTUs 105ton RTUs • Installation of two 850ton centrifugal chillers • Optimization of BAS system • New Drives for process BAS System water pumps • Idling of equipment New Drives when spaces are not occupied 23 Chillicothe Plant
Actions Taken Activities Taken New RTUs New Chillers • Installation of five new 105ton RTUs • Installation of two 850ton centrifugal chillers • Optimization of BAS system BAS System • New Drives for process water pumps New Drives 24 Chillicothe Plant
The Results 500 kWh / truck Electrical energy used to produce a truck was reduced from ~1,500 kWh / unit to ~1,000 kWh / unit over the three year period. A daily reduction of 85,000 kWh!!! 25 Chillicothe Plant
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