COMPETENCY CENTERS PRODUCTION CENTERS EUFI TURKEY - 206 empl. 250 M - - PowerPoint PPT Presentation

Alabama E3 Experience

250 M€ 173 M€ 147 M€

CLOSE TO OUR CUSTOMERS ON 3 CONTINENTS: A FAST RESPONSE ALWAYS CLOSE AT HAND

Beynost - FRANCE - 827 empl. EFEC - CHINA - 222 empl. EFIS - FRANCE - 105 empl. EUFI – TURKEY - 206 empl. EFC - USA - 150 empl.

COMPETENCY CENTERS PRODUCTION CENTERS

1500 employees worldwide

SALES, DEVELOPMENT, PRODUCTION & LOGISTICS

P R O D U C T I O N

• 1500 Employees
• 53% Tier 1 Sales
• 100% Automotive

250 M€ 173 M€ 147 M€ 183 M€

2006 2011 2012 2015 NORTH AMERICA – ELECTRICFIL CORPORATION

• 150± employees
• Specialized in Powertrain

instrumentation (sensors and mechatronic systems)

Plastic Trays Corrugated Packaging Shrink Wrap Runners from Overmold Operations Subassembly Waste Clippings Plant Floor Recycling Station Electricfil Corporation recycles 99% of all production by-products. (examples shown) We also recycle maintenance by-products such as used oil, bulbs, etc. Used Mold Waste

Plant Floor Recycling Efforts

Why We Joined the E3 Program

• Initial Goal of Reducing our Impact on the

Environment

• Main focus to become landfill free
• Services were provided at either no charge or at very

low cost

• No-risk with immediate impacts identified
• Benefits recognized immediately making it easy for

Management to support

E3 Assessments and Services

• Lean Assessment
• Practical Energy Assessment
• WRATT – Equipment life cycle costing
• 2 Kaizen Events
• Mixed Model Production at potting
• Tool changeover at overmolds
• Green Specialist Training – Dumpster Dive
• Assisted in creating Energy and CO2 Calculators

• Green House Gas Emissions/Carbon Footprint = 1795.6 Metric Tons
• Excellent recycling program
• Excellent landfill waste reduction efforts
• Energy Saving Opportunities = $14,946.47
• Lighting = $12,022.51
• Compressed Air = $1510.00
• Motors = $855.36
• Belts = $558.60
• Additional Energy Savings Opportunities:
• Building Openings
• Overhead Doors
• Office Equipment
• Exit Signs
• Thermostat Settings

Initial E3 Assessment

Existing Light Fixtures

• 18 400W Low Bay Metal Halide

Fixtures

• 40 400W High Bay Metal Halide

Fixtures

• 33 96” T12 2-Lamp Fluorescent

Fixtures

• 2 48” T12 2-Lamp Fluorescent

Fixture

• Existing Lighting Level – Ave.

27.57 FC/sq. ft.

Lighting Project

Lighting Project Cont.

Proposed Light Fixtures

• 12 48” T8 6-Lamp

Fluorescent Fixtures w/occupancy sensors

• 29 48” T8 8-Lamp

Fluorescent Fixtures

• 11 48” T8 8-Lamp

Fluorescent Fixtures w/occupancy sensors

• 2 96” T12 2-Lamp

Fluorescent Fixtures – switched

• Proposed Lighting Level –
• Ave. 34.11 FC/sq. ft.

Existing Estimated Usage and Cost to Operate

• 31.76 Kilo-Watts of Demand
• 198,356 Kilo-Watt Hours of Usage Per Year
• $15,868 Annual Energy Cost to Operate

Proposed Estimated Usage and Cost to Operate

• 12.70 Kilo-Watts of Demand
• 79,247 Kilo-Watt Hours of Usage Per Year
• $6,340 Annual Energy Cost to Operate

Proposed Lighting Configuration Savings for EFC…

• 19.06 Kilo-Watts of Demand
• 119,109 Kilo-Watt Hours of Usage Per Year
• $9,528 in Annual Energy Cost to Operate
• $950 in Annual HVAC Cost
• Combined Utility Cost Savings of Nearly $10,500

Annually! Lighting Project Results

Compressed Air Assessment

Note: Just one 1/16” air leak @ 100 psi cost over $650 @ 10 cents/kwh. Also for every 2 psi reduction in system pressure, there is 1% savings in power. For example, if your shop air is set at 125 psi and 100 psi would work just fine, that would be a savings of 12.5% of the electricity used to run compressors.

No. Size of Leak Cost Savings 1 1/64 $31.00 2 1/32 $122.00 3 1/32 $122.00 4 1/32 $122.00 5 1/32 $122.00 6 1/16 $495.50 7 1/16 $495.50 Total Savings: $1,510.00 More Compressed Air Opportunities

• Reduce compressed air

system pressure

• Use drain traps that

have automatic drains

• Remove air lines used

for “blow off”

• Is compressor air intake

from clean cool location

• Turn off air when not

being used

• Opportunity to cycle

compressors

• Periodically change

filters and do cleaning

• Opportunity to use

electric motors, not pneumatic motors

Energy Saving Opportunity

Energy Saving Opportunity

Energy Saving Opportunity

Energy Saving Opportunity

• Reduced landfill bound waste from 40 yards to 2 yards per week
• Recycle 99% of production scrap waste

YTD Monthly Avg General Waste per Employee

1 2 3 4 5 6 7 8 9 2010 2011 2012 2013

Avg Headcount per Year

20 40 60 80 100 120 140 160 2010 2011 2012 2013

• 2013 Recycling Rebates ≈ $7200
• We will make $4975 on our waste by year’s end
• 2013 Waste Disposal Costs ≈ $2225

E3 Training at Work

• Sealed base of plant garage doors and insulated panels to reduce

energy loss

• Installed efficient hand-dryers vs paper towels to reduce waste
• Reduced energy usage by over 485,000 kWh per year
• Reduced related CO2 emissions by over 630,000 lbs per year
• Awarded the 2011 Sustainability in Manufacturing Leadership Award

from Alabama Technology Network the Business Council of Alabama

• Awarded the 2012 Alabama E3 Environment Achievement Award
• Changed mindset of employees to focus more on sustainability.

Further E3 Impacts

• Feb. 21st 2013 – EFC COMMUNICATION MEETING

THANK YOU