Energy Management at Texas Instruments Paul Westbrook Sustainable Development Manager, LEED AP Texas Instruments Facilities, Energy Team Senior Member of the TI Technical Staff Senior Fellow, US State Department Energy and Climate Partnership of the Americas (ECPA)
Outline • TI Overview • History of Energy Efficiency at TI • Current Strategy • Results and Goals
TI Businesses 2011 TI Revenue by Segment: $13.7 billion Ultra low power, high capability processors and analog chips Education Technology $0.4 billion Semiconductor $13.3 billion LED lights E-bikes Wind turbine – (6) TI chips iPad Smart Phones
Our Process - Simplified Wafer Fabrication (fab) Assembly / Test (A/T)
TI’s Global Presence Approximately 34,000 employees worldwide Chengdu Aizu Chengdu Fab Aizu Fab 14,000 in Asia 2,500 in Japan 3,000 in Europe Miho LEGEND Miho Fab 14,500 in The Americas Wafer Fabs Hiji Greenoc Assembly / 10,000 in Texas k Test Hiji Fab Bump Hiji A/T GFAB 9,000 in North Texas 8,200 in Dallas area Freising Portland, ME FFAB Aguascalientes Taipei MFAB TMX TITL Dallas DFAB DMOS5 Malaysia Kuala Lumpur DMOS6 Melaka SFAB DHC Houston Baguio City RFAB HFAB Baguio DBump HBump Pampanga Manufacturing, design, or sales Clark 34 large sites operations in more than 30 13 wafer fabs 24 million gsf countries serving over 80,000 6 assembly/test sites customers
What is a Wafer Fab? A very large, clean facility … • Total space: 1.1 million square feet • Cleanroom space: 284,000 square feet
What is a Wafer Fab? … that fabricates very small chips on large silicon wafers. Hair = 80,000 nm diameter 2 mm 39 nm 2 mm 86 nm 300 mm diameter Gate = 39 nm 1,500-45,000 chips each diameter @450 wafers/day >3 billion chips/year DNA = 2 nm Atom = 0.1 nm diameter diameter
Interesting Fact • The total energy required to design, manufacture, package, sell, and support a single chip is: <0.25kWh • That’s the amount of energy needed to run an old 60W incandescent light bulb for: 4 hours
History of Energy Efficiency at TI • Formal energy management organization formed in 1973 – Custom built TI lighting timers and energy management programs – Implemented and documented energy saving projects – Tracked and reported energy use – Good maintenance practices to keep systems operating efficiently – Over 7 million gallons of thermal storage
Significant Step • New Wafer Fab – RFAB – Planning began in 2003 – Integrated design with focus on efficiency – First Semiconductor Fab to seek LEED certification – Drove efficiency awareness in mfg tool suppliers • Existing Buildings – RFAB success led management to request more focus on existing buildings – Dedicated utility savings capital budget was established in 2006
Current Strategy • Never Miss an Opportunity on a New Building – LEED-NC for all new buildings • Data Driven Direction and Decisions – Track energy indices and apply limited resources to the right projects • Best Practices – Developed a list of best practices and assess sites for compliance • Energy Assessments – Visit sites to educate, assist, and learn from them • Dedicated Utility Saving Project Capital Funding – Averaging around $5M per year for utility saving projects
Start with the Data • Energy Use Office/Data – Wafer fabs are predominant Center, 9% • Energy Source AT, 21% – Purchased electricity is the primary energy source Other, 3% Gas, 14% Fab, 69% Electricity, 83%
Wafer Fab Data • Manufacturing Equipment – Largest direct energy use – Largest source of waste heat 2011 Fab Energy Assessment ISMI 10 facilities: (9) 300mm, (1) 200mm
Assembly Test and Office Data PCW 2% Misc (PVAC, DI, Exhaust MUA, Steam, etc) 2% Lighting Texas 5% 3% Misc Water Heating Recirc Air 5% 5% 8% Heating 6% Process Eq. Office CDA Lighting 45% Equipment 42% 14% 18% Cooling/ CHW Ventilation 21% 24% Assembly / Test (A/T) Typical Texas Office
Energy Curves • Energy Curves – Energy use per unit of production plotted against % loading of the Energy / Pattern facility – Goal is to lower and flatten the curve – We track curves for AT sites too – We track water use curves as well 100%
Best Practices • Developed internal lists of best practices by major system: – Chilled Water – Heating Ventilation and Air Conditioning (HVAC) – Compressed Dry Air (CDA) – Exhaust – Lighting – Water • Each system has dozens of items to assess – These items often generate new project ideas
Best Practices – Key Items • Sites list their implementation status ( Y es, E valuated, N ot Evaluated, Not Applicable N/A ) • For 2012 we are focused on 39 key items across the six system categories • An example of two of the items are listed above
Energy Assessments • Teams of 4-5 people visit all major sites to assess opportunities – Rotating members visit approximately 4 sites per year • Provides good sharing and learning between sites – Teams drawn from members of other sites • Allows Energy Champions (we have one champion at each site) to meet and establish relationships
Dedicated Utility Capital Funding • Established funding in 2006 • Dedicated capital budget for utility saving projects – Average of about $5M/year in capital funding – Capital projects submitted and ranked quarterly – Average of 32 capital projects per year with a 2.1 year average payback • Sites fund their own expense projects – Average of 80 expense projects per year with a 9 month avg payback • Energy efficiency is always more affordable than any type of energy generation
Utility Savings Capital History
Compounding Savings – Savings compound so our 2012 energy cost is $34M lower than it would have been without this activity
Results and Goals • Energy Index – Total energy use – Energy use per chip manufactured – Down 39% from 2005 to 2010 – Set goal for an additional 45% reduction between 2010 and 2015
TI Highlights • First LEED Gold wafer fab in the world – RFAB – Admin and Fab certified separately – both LEED Gold – Set new efficiency record already (better by 26%) • First LEED certified building in the country of the Philippines • LEED Gold Assembly Test site in Clark, Philippines • Integrating LEED for Existing Building credits into our Best Practices TI has over 2 million square feet of LEED certified buildings worldwide
TI Challenges • Cultural differences – Some sites are more energy conscious than others • Involving everyone – How do we get every employee to consider energy efficiency as part of their job? • Integrating new facilities and used equipment – TI purchasing used equipment and existing facilities • Variable loading – How do we make the energy use as variable as the factory loading
The Negawatt Negawatt (n) - a measure of energy efficiency; a unit in watts of energy saved Solar and wind may be sexy . . . . . . but efficiency yields the best financial and environmental benefits
Thank You TI Corporate Citizenship Report www.ti.com/ccr Paul Westbrook p-westbrook@ti.com
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