2019 Better Buildings Summit Better Practice Toyota ESCO Process 1 - PowerPoint PPT Presentation

2019 Better Buildings Summit Better Practice – Toyota ESCO Process 1

Toyota North America Operations Vehicle Assembly (8) CAPTIN 1985 Unit Plant (7) Research & Development (3) Manufacturing Purchasing TMMC 1988 Production Engineering TMMC 2 2008 Georgetown, KY Corporate Headquarters SIA 2007 TEMA Plano, TX 1996 TMMI TMMWV 1999 1998 Toyota & Mazda Joint Venture TMMK 1988 Huntsville, AL BODINE 1990 TABC 1971 BODINE 2005 29 Million Sq.Ft. TMMAL 2003 TMMBC 2004 TMMMS 2011 TMMTX 2006 2

CARBON http://www.toyota-global.com/sustainability/environment/challenge2050/ WATER • Zero CO 2 emissions in all plants worldwide by 2050 • 2030 Milestone: Reduce CO 2 MATERIALS emissions from all plants worldwide by 35% from 2013 baseline How? Innovative Technology, Renewable Energy and *Kaizen Activity BIODIVERSITY *ESCO supports the Kaizen Activity 3

What is the Energy Savings Collaboration (ESCO)? Internal energy savings and minimization process • Identify/implement CO 2 reduction opportunities in manufacturing • Support Toyota’s 2050 Challenge • No impact to – Safety, Quality and Production • Team Member Development (management, production, maintenance, engineers, group leaders, contractors and students) • Promote reduction activities in daily work 4

What’s the difference? ESCO Treasure Hunt • Focus is on plant operations during • Focus is on plant operations when “all times” “sleeping” • One-to-two week, deep dive • One-to-three day, quick fixes • Walk throughs focus on: • Walk throughs focus on: • High level and detailed inspection; processes, set • High level inspection; equipment running, points, startup/shutdown, human behaviors, leaks, lights on, etc. ability to ask questions while plant is running, etc. 5

How does the ESCO Process work? 2 months +12 months 0 months (Pre-ESCO) (Post-ESCO) A B C PREPARATION SITE INVESTIGATION IMPLEMENT Genchi Genbutsu (go & see): Kaizens discussed: Study where to look: • Onsite 1-2 weeks • Low/no cost • Data Analysis • Audit SEUs and processes • Confirm R&R • Evaluate KPIs • Perform energy calculations • Secure project funding • Determine gaps • Report findings to Plant Executives • Expect one year to implement • Identify initial kaizens • Measure & verify • Create team • Follow-up 6

Let’s Talk Numbers ESCO Process Annual CO 2 Savings 150 2 33 CO 2 (kMT) 100 1 64 140 50 43 0 Completed Ongoing Planned Total To date 8 ESCO activities (2016-2019) have been completed in which: 155 low/no cost, low payback kaizens discovered & implemented by end of 1 2019 186 kaizens w/ longer payback (> 2 yrs.) being reviewed to implement 2 7

What are some examples of kaizens discovered? 100 MT/washer 2,600 MT High Speed Valve CO 2 Savings CO 2 Savings 90psi 500psi Compressed air to electric blowers in High pressure tank to reduce washers compressor start ups Booster 300 MT 360 MT CO 2 Savings CO 2 Savings New oven burners allow Utilize waste heat from heat set back during non- treatment production times 8

What are the challenges? • Time • Payback length • Project Funding • Manpower 9

Summary • New opportunities added to master list • Kaizens kept in database for sharing • Educate Team Members • ESCO ongoing process • Toyota effectively growing energy team with every ESCO 10

T HANK YOU 11