at Texas Instruments Paul Westbrook Sustainable Development - - PowerPoint PPT Presentation

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

Semiconductor $13.3 billion Education Technology $0.4 billion

iPad

Ultra low power, high capability processors and analog chips

Wind turbine–(6) TI chips LED lights E-bikes Smart Phones

Our Process - Simplified

Wafer Fabrication (fab) Assembly / Test (A/T)

Freising FFAB Dallas DFAB DMOS5 DMOS6 SFAB DHC RFAB DBump Aguascalientes TMX Baguio City Baguio Malaysia Kuala Lumpur Melaka Taipei TITL Miho Miho Fab Hiji Hiji Fab Hiji A/T Houston HFAB HBump LEGEND Wafer Fabs Assembly / Test Bump Pampanga Clark Aizu Aizu Fab Chengdu Chengdu Fab

TI’s Global Presence

Approximately 34,000 employees worldwide

14,000 in Asia 2,500 in Japan 3,000 in Europe

14,500 in The Americas

 10,000 in Texas  9,000 in North Texas  8,200 in Dallas area

Manufacturing, design, or sales

• perations in more than 30

countries serving over 80,000 customers

34 large sites 24 million gsf

Portland, ME MFAB Greenoc k GFAB

13 wafer fabs 6 assembly/test sites

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.

300 mm diameter 1,500-45,000 chips each @450 wafers/day >3 billion chips/year

2 mm 2 mm

86 nm 39 nm

Hair = 80,000 nm diameter DNA = 2 nm diameter

Gate = 39 nm diameter

Atom = 0.1 nm diameter

Interesting Fact

• The total energy required to

design, manufacture, package, sell, and support a single chip is:

• That’s the amount of energy

needed to run an old 60W incandescent light bulb for: <0.25kWh

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

• perating 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

• n 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

AT, 21% Fab, 69% Office/Data Center, 9%

Electricity, 83% Gas, 14% Other, 3%

• Energy Use

– Wafer fabs are predominant

• Energy Source

– Purchased electricity is the primary energy source

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

Process Eq. 45% CHW 21% CDA 14% Recirc Air 8% Lighting 3% Exhaust 2% PCW 2% Misc (PVAC, DI, MUA, Steam, etc) 5%

Assembly Test and Office Data

Lighting 42% Cooling/ Ventilation 24% Office Equipment 18% Heating 6% Water Heating 5% Misc 5%

Texas

Assembly / Test (A/T) Typical Texas Office

Energy Curves

Energy / Pattern

• Energy Curves

– Energy use per unit

• f production

plotted against % loading of the 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 (Yes,

Evaluated, Not 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

• ur 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