Workshop G
Energy Savings Champions – Best Practices & Case Studies in Energy Reduction & Energy Efficiency in Award-Winning Industrial Corporations
Tuesday, February 18, 2020 1:45 p.m. to 3 p.m.
Workshop G Energy Savings Champions Best Practices & Case - - PDF document
Workshop G Energy Savings Champions Best Practices & Case Studies in Energy Reduction & Energy Efficiency in Award-Winning Industrial Corporations Tuesday, February 18, 2020 1:45 p.m. to 3 p.m. Biographical Information Mark A.
Energy Savings Champions – Best Practices & Case Studies in Energy Reduction & Energy Efficiency in Award-Winning Industrial Corporations
Tuesday, February 18, 2020 1:45 p.m. to 3 p.m.
Biographical Information
Mark A. Brady, Plant Engineer, Bridgestone APM Company P.O. Box 450, 235 Commerce Way, Upper Sandusky, Ohio 43351-0450 419-731-2241 Fax 419-294-3147 mabrady@bapm.Com Mark started his industrial career in 1978 with Guardian Automotive Glass in Upper Sandusky Ohio. He spent the majority of his time there in the maintenance department taking on various responsibilities. Plant power was one, including the operation of the primary sub-station that fed the plant. He always involved himself in special projects involving modernization, productivity and cost effectiveness. After fifteen years he decided to change automotive materials and started working with rubber at Bridgestone Auto Parts Manufacturing. Bridgestone APM has been his home for the last twenty-seven years, first in maintenance and the last ten years in the building aspect of things. His current responsibilities as plant engineer include the building, plant air, power, ventilation, lighting and equipment installation. All of these areas have lent themselves to energy saving projects in recent years thanks largely to the help and encouragement of AEP Ohio. The Grid-Smart program and CEI groups have helped greatly with ideas and direction on what can be done and how to get them implemented. As a corporation, we appreciate their help and experience for sustainability and progress in our goal to be more resource conscience in our production facilities. Andrew K. McCabe, Manager-Business Programs, AEP Ohio 700 Morrison Rd, Gahanna OH 43230 614-883-7876 akmccabe@aep.com Andy started his energy career with AEP in New York City in 1976 as a station design
Charleroi, PA to manufacture high-voltage circuit breakers. In 1997, AEG was purchased by GEC Alsthom with Andy become US T&D Commercial Director. In 2018, Andy returned to AEP in T&D asset management. In 2010, Andy was promoted to Manager of Business programs for Energy Efficiency and Peak Demand reduction. In 2019 Andy was promoted to Portfolio manager for Energy Efficiency and Peak Demand reduction. Andy is a graduate of Polytechnic Institute of Brooklyn with a B.S. in Electrical Engineering and received an MS is Electrical Engineering from Polytechnic Institute of New York. Andy is a CEM, CEA and REA. Andy is a Life member of IEEE.
Biographical Information
Gary Hendrickson, AEP Ohio CEI Team 445 Hutchinson Ave. Suite 300, Columbus, OH 43235 740-974-6587 – Cell Gary.hendrickson@clearesult.com Gary Hendrickson is an engineering manager who has been formally trained in TQM, Strategic Planning, Project Management, Product Development, Lean & Six Sigma methodologies with
delivered improvements in product quality, process efficiency and supplier performance. His additional strengths are data analysis, drive to achieve goals, ability to quickly learn new disciplines, motivating others to eliminate waste/reduce cost and improve customer service
Total Quality Management • TPM • Project Management • Lean Six Sigma • Strategic Planning • Supply Chain Strategies • Supplier Management/Development • 5S Visual Management • Statistical Process Control • FEMA • Work Force Development • Value Stream Mapping • ISO9000 • TS16949 • Documentation management & vintage control • Re-engineering Techniques • New Product Introduction • Kaizen • CAPA (8-Disciplines) • Balanced Score Card Since November 2012, Gary has served as SEM Program Manager for CLEAResults. Through a series of SEM workshops and providing individual coaching, the client learns to apply the principles of Strategic Energy Management to reduce their energy intensity by 5% year-over-year.
their superior energy reduction performance.
performance
SEM program graduates go on to become ISO 50001 certified. Prior to his experience with CLEAResults, Gary was the Supplier Quality Improvement Manager At Cummins Inc. managing a Supplier Quality Team of 5 engineers and 10 technicians for current and NPI product. Work with the Plant Leadership team to develop long term Quality improvement plans to continuously improve our supply base.
supplier by 85%
programs resulting in the prevention of 6 major quality spills.
resulting in a 54% reduction in 7 months.
improvements in supplier response to close CAPA s; we reduced the time to close a quality issues by 37%. More biographical information can be found at: https://www.linkedin.com/in/glhendrickson/
110 6 Bulb T5 Fixtures Lumen Approx. 25,800 Watts @ 351 / Fixture 12 Units on Motions 132 Albeo LED Fixtures Lumen Approx. 36,000 Watts @ 221 /Fixture 49 Units on Motions Watts @ 80% / 177 Lumen 80% / 28,800 Optics 120° / 5000K GE Daintree Controls Weekend Schedules Daylight Harvesting Motion Detectors
Former Former Improved Improved Luminaire Description 6 Lamp T5 HO GE ABV3 LED Per Luminaire Wattage 351 177 @ 80 % System Watt 36,610 14,603 Annual Kilo-Watt Hours 338,224 127,918 Annual Energy Costs $32,131 $12,152 Project Cost With Additional Wiring $98,000 AEP Ohio Incentives Program Rebate $27,000 Simple Payback In Years 3.5 Five Year Cash Flow $29,968
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Renton, WA Montreal, CN Mexicali, MX Chillicothe, OH
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Environment
recorded as part of all capital projects
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(Kenworth’s) Energy & Environmental goals
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Compressed Air Setpoint
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Pressure air compressor with air multipliers (boosters)
setpoint within the factory
rooms Occupancy Sensors Air Multipliers
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control OCC v. UNOCC of HVAC equipment
compressed air equipment
sequencing Building Automation System Compressed Air System
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105ton RTUs
850ton centrifugal chillers
system
water pumps
when spaces are not
New RTUs BAS System New Drives LED Lighting
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Activities Taken
105ton RTUs
850ton centrifugal chillers
system
water pumps New RTUs BAS System New Chillers New Drives
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Electrical energy used to produce a truck was reduced from ~1,500 kWh / unit to ~1,000 kWh / unit over the three year period. A daily reduction of 85,000 kWh!!! 500 kWh / truck
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$193,400
$315,700
42.8M kWh
38.3M kWh
4.5M kWh
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Suppliers and vendors that helped make these achievements possible.
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