SUSTAINABILITY SUSTAINABILITY NORTH AMERICA NORTH AMERICA SGNA COMPRESSED AIR CHALLENGE SUMMARY
SUSTAINABILITY NORTH AMERICA WHY COMPRESSED AIR? Inappropriate • Compressed air is the most costly Uses, 9% Artificial source of energy usage at many of our Demand, 4% plants. • A ½” leak can cost a site up to $115,000 per year if left unchecked. Leaks, 26% Production, 61% • Over 48% of our sites lack air leak tracking programs. CertainTeed Roofing Facility • 37% of sites want a compressed air Compressed Air Flow Distribution audit 2 / SGNA Compressed Air Challenge
SUSTAINABILITY Sta te of SGNA c ompre sse d a ir: NORTH AMERICA n a 2017 surve y o f 94 site s, 91% have c o mpre sse d air syste ms I 40% ne e d to be re plac e d Co nditio ns o f SGNA Co mpre sse d Air Syste ms 50 45 40 35 lac k air le ak trac king 48% 30 pro grams 25 20 15 10 want a c o mpre sse d 37% 5 air audit 0 Syste ms are ne w Syste ms are We do no t assign T here is an A c o mpre sse d o r re c e ntly mo re than 15 pe o ple to trac k e stablished le ak air syste m update d ye ars o ld do wn air le aks de tec tio n/ re pair assessme nt pro gram in wo uld be ne fit plac e my site • Co mpre sse d air pre fe rre d ve ndo r • L e ak de te c tio n and re pair pro grams T he Sustainability Ne two rk re c o mme nds: • DOE I NPL T s fo r c o mpre sse d air • E ne rgy/ c o mpre sse d air audits 3 / SGNA Compressed Air Challenge
SUSTAINABILITY NORTH AMERICA THE SUSTAINABILITY NETWORK FORMED COMPRESS IT Pote ntia l Annua l Sa ving s: 26 GWh of e ne rg y WHEN: October 29 – December 31 $2.5M WHO: Open to all SGNA, with teams of up to 5 of WHAT: A three-month, voluntary competition to see which site e le c tric ity can identify and fix the most leaks, and make improvements to c osts their compressed air system (both in operations and management) 4 / SGNA Compressed Air Challenge
SUSTAINABILITY NORTH AMERICA HOW DOES IT WORK? SITES SUBMIT TASKS IN AN ONLINE FORM FOR POINTS Points Task Description 5 Team name and photo 20 Compressed air audit completed in past 2 years 30 Form a compressed air team and/or leak detection and repair program 10 Monitor your compressed air system (i.e. sensors, meters) 20 Showcase use of at least (2) Sustainability Network compressed air resources 10 per leak Find leaks (2 pts) and Fix leaks found (8 pts) BONUS 1st place – 100 Innovative employee engagement (i.e. Smack talk video, video of team, team t- 2nd place – 60 shirts, presentation, etc. 3rd place – 40 5 / SGNA Compressed Air Challenge
SUSTAINABILITY NORTH AMERICA HOW DO SITES REPORT LEAKS FOUND AND FIXED? MULTIPLE LEAKS SUBMISSION FORM V2.0 6 / SGNA Compressed Air Challenge
SUSTAINABILITY NORTH AMERICA SITE PARTICIPATION AS A RESULT OF THIS CHALLENGE… BUSINESS INVOLVEMENT sites scheduled compressed air 3 19 SITES TOTAL audits 7 sites formed a compressed air NO. OF SITES 4 5 team and leak tracking system 3 2 1 1 sites utilized SGSN compressed 6 air resources sites attended the Compressed 24 Air Challenge webinar 7 / SGNA Compressed Air Challenge
SUSTAINABILITY NORTH AMERICA HOW WAS THIS COMMUNICATED? CHALLENGE GUIDELINES DOCUMENT 8 / SGNA Compressed Air Challenge
SUSTAINABILITY NORTH AMERICA HOW WE ENCOURAGED SITES TO PARTICIPATE WEEKLY POSTING OF LEADER SCOREBOARD Percent Ranking Site Name Business Team Name Points Leaks Found Fixed Oxford, NC CT Roofing Weeki Leaks 1,413 146 82% 1st Jackson, MI CT Siding Leak Stoppers 1,076 100 96% 2nd 3rd Cody, WY CT Gypsum Cody 576 152 22% Ottawa, ON CT Insulation Whistle Breaker 368 67 25% 4th 5th Avery, OH CT Roofing The Avery Avengers 363 28.5 100% Ennis, TX CT Roofing Full of Hot Air 348 24 54% 6th 7th Moundsville, WV CT Gypsum VolunTold 304 32 63% Piedmont, MO CT Roofing Max-Air-Mizers 268 57 30% 8th Wilmington Compressed Wilmington, CA CT Roofing 194 83 0% 9th Air factioN (Wi-CAN) 10th Nashville, AR CT Gypsum Mystery Clan 189 48 21% 9 / SGNA Compressed Air Challenge
SUSTAINABILITY NORTH AMERICA HOW WE ENCOURAGED SITES TO PARTICIPATE BIWEEKLY CONTESTS AND PRIZES 2 nd Week 4 th and 6 th Week 8 th Week 10 th Week Register Team Find and Fix 10 Innovative Employee Best Team Name Name and Photo Leaks Engagement SAINT - GOBAIN YE T I T UMBL E RS SMART PL UGS SMART L IGHT S SMART PL UGS ANKE R POWE R BANKS 10 / SGNA Compressed Air Challenge
SUSTAINABILITY NORTH AMERICA INTERNAL WEBSITE FOR WEEKLY UPDATES AND RESOURCES 11 / SGNA Compressed Air Challenge
SUSTAINABILITY NORTH AMERICA INTERNAL WEBSITE FOR WEEKLY UPDATES AND RESOURCES BEST PRACTICES AND RESOURCES SGNA Compressed Air Challenge 12 /
SUSTAINABILITY CHALLENGE 1 ST PLACE PRIZE NORTH AMERICA Weeki Leaks was a fierce contender, closely trailing behind Leak Stoppers for all but one week, with dramatic improvements in the last couple weeks bringing them to the top. Their site worked hard, took the Challenge seriously, and were rewarded 1st PLACE PRIZE Solar-Charging Weeki Leaks 146 leaks found Backpacks CT Roofing – Oxford, NC 82% of leaks fixed 13 / SGNA Compressed Air Challenge
SUSTAINABILITY CHALLENGE 2 ND PLACE PRIZE NORTH AMERICA Also a fierce contender, Leak Stoppers led the pack almost every week, finding and fixing many leaks both fast and early. How? Leak Stoppers held an internal competition for employees to find leaks with the Slogan "Help us find our leaks and we will help you fix yours." The winners were given a gift certificate to an auto repair shop. 2nd PLACE PRIZE Amazon Echo Dots Leak Stoppers 100 leaks found CT Siding – Jackson, MI 96% of leaks fixed 14 / SGNA Compressed Air Challenge
SUSTAINABILITY NORTH AMERICA BONUS POINTS FOR INNOVATIVE EMPLOYEE ENGAGEMENT 1 ST PLACE PRIZE Full of Hot Air created a participant video of the site finding air leaks. Almost all departments got involved! Please enjoy this suspenseful, epic film depicting air leaks at the CertainTeed Ennis plant! 1 st PLACE PRIZE Smart Lights Full of Hot Air 19 leaks found CT Roofing – Ennis, TX 5% of leaks fixed 15 / SGNA Compressed Air Challenge
SUSTAINABILITY NORTH AMERICA TEAM NAME COMPETITION The Team Name competition was administered on a Google Form, and the night of the deadline prompted a fierce competition between VolunTold and Weeki Leaks , with the winner changing every hour! The sites got all employees to participate. 1 st PLACE PRIZE Smart Plugs 16 / SGNA Compressed Air Challenge
SUSTAINABILITY NORTH AMERICA POSITIVE IMPACTS • Promotes the development of a continuous compressed air management and operations team • Highlights best practices at different sites and provides the opportunity for sharing • Sites found 824 leaks of varying sizes, and repaired 47% of them • The collective fixed leaks resulted in potential energy savings of 26 GWh of electricity, or $2.5 million (assuming leaks found persisted for a year and are fixed). This is 5% of the 2018 energy spend for all 19 sites. ELECTRICITY CONSUMPTION ELECTRICITY COSTS 17 / SGNA Compressed Air Challenge
SUSTAINABILITY NORTH AMERICA CHALLENGE GOALS SUCCEEDED Provide a fun, low-cost way for sites to tackle the compressed air issue Empower sites to create their own solutions while still utilizing the resources provided by the Sustainability Network Help each site to develop or enhance a continuous and sustainable compressed air operations and management system in order to keep down compressed air costs Spur quick energy savings that could make an impact on the next year’s environmental reporting goals 18 / SGNA Compressed Air Challenge
SUSTAINABILITY NORTH AMERICA Thank You
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