Upload
juliana-quarles
View
220
Download
3
Tags:
Embed Size (px)
Citation preview
© 2013 Toyota Motor Corporation Australia Limited 1
TMCA and the EEO
Applying Toyota Business Practices to Energy Efficiency
© 2013 Toyota Motor Corporation Australia Limited 2
Toyota Australia Overview
MELBOURNE
Port Melbourne• Corporate Head Quarters (CHQ)
Altona Manufacturing Plant• Engine, Foundry, Press, Paint and Assembly
SYDNEY• Sales & Marketing
REGIONAL OFFICES =
LOCAL SUPPLIERS 1,794 Purchase value: A$1.65 billion
TMCA EMPLOYEES• Total = 4,184• Nationalities = 60+
DEALERS Toyota: 210, Lexus: 19 Employees: 12,615
•Townsville •Brisbane
•Sydney •Melbourne
•Adelaide •Darwin
WA Distributor
© 2013 Toyota Motor Corporation Australia Limited 3© 2013 Toyota Motor Corporation Australia Limited 3
Toyota is Australia’s biggest manufacturer of cars
© 2013 Toyota Motor Corporation Australia Limited 4© 2013 Toyota Motor Corporation Australia Limited 4
In 2012 nearly 100,000 Camry, Camry Hybrid and Aurion left our Altona factory.
© 2013 Toyota Motor Corporation Australia Limited 5© 2013 Toyota Motor Corporation Australia Limited 5
Toyota considers Sustainability in all parts of our operation
© 2013 Toyota Motor Corporation Australia Limited 6© 2013 Toyota Motor Corporation Australia Limited 6
Carbon Foot Print of a Camry Embedded energy in Materials = 5.98 tonne/car
Parts Manufacture (Suppliers) = 2.64 tonne/car
Vehicle Manufacture = 1.50 tonne/car
Parts and Vehicle Logistics = 0.093 tonne/car
Sales Activities = 0.21 tonne/car
Lifetime use of vehicle = 44 tonne/car
A/c gas= 0.65 tonne
Offices & Warehouses0.13 tonnePer vehicle
© 2013 Toyota Motor Corporation Australia Limited 7
EEO as part of the response
The EEO is a part of Toyota Australia’s response strategy to limit the impacts of the Clean Energy Future Scheme
The EEO is used as a management tool in the overall response which also includes:•Toyota’s Guiding Principles•The Toyota Earth Charter•The TMAP Regional Action Plan•Toyota Australia’s Environmental Action Plan•Annual Environmental KPI’s
© 2013 Toyota Motor Corporation Australia Limited 8© 2013 Toyota Motor Corporation Australia Limited 8
TMCA Activity – “Axe the Tax”
To encourage Energy Efficiency in manufacturing, TMCA had an ‘Axe the Tax’ campaign in 2012 to:• Implement Actions to
reduce the impact of the CEFS
• Offset additional cost through identified savings
• Encourage all Shops to put forward Energy Efficiency Initiatives
© 2013 Toyota Motor Corporation Australia Limited 9
Challenges
The key challenge with using the EEO processes for Toyota Australia is turning a legislative requirement into a useful business tool suitable to our industry.How do we reconcile:•Data vs Information•Legislative vs Company requirements (i.e Payback criteria)•Energy vs Carbon•Toyota systems vs Government systems
© 2013 Toyota Motor Corporation Australia Limited 10© 2013 Toyota Motor Corporation Australia Limited 10
EEO and TEMS
• TMCA integrates EEO through our EMS
• Each shop has a multi disciplinary TEMS team
• Each TEMS team has access to support from engineering and Corporate groups
• Each TEMS team is tasked with finding and implementing improvement ideas
© 2013 Toyota Motor Corporation Australia Limited 11© 2013 Toyota Motor Corporation Australia Limited 11
The PDCA Cycle
TMCA uses the PDCA process to implement energy efficiency projects• Plan – The TEMS teams look at
identifying new projects and gather all relevant data (including baselines etc).
• Do – The projects are assessed, approved and implemented (taking account of EEO requirements)
• Check – the performance of the project is measured against expectation (daily, weekly, monthly)
• Act – The project is integrated, standardised and shared
© 2013 Toyota Motor Corporation Australia Limited 12© 2013 Toyota Motor Corporation Australia Limited 12
Case Study: VSD Drives - Background
• The supply & exhaust fans in cavity wax are connected in direct online configuration
• They have a current 6 times the motor rated current at start-up
• This results in unnecessary energy being consumed.
• During Production time, the fans are running at full capacity and are being left on during non production time thus using excess energy (Gas & Electricity).
• Maintenance regularly have to change and repair motor belts & pulley.
• The conditions of these booths have changed as they are now dry booths.
Before Kaizen:
© 2013 Toyota Motor Corporation Australia Limited 13© 2013 Toyota Motor Corporation Australia Limited 13
Case Study: VSD Drives - Activity
• Undertake detailed analysis of current power consumption
• Install Inverter to be able to control speed of Fans
• Consult with all stakeholders regarding• Quality concerns• Maintenance issues• OH&S concerns
Activity – Install Variable Speed Drives:
© 2013 Toyota Motor Corporation Australia Limited 14© 2013 Toyota Motor Corporation Australia Limited 14
Case Study: VSD Drives - Results
After Kaizen – Supply Fan:
• Reduced frequency from 50 Hz to 45 Hz and then 40 Hz
• Power reduction from 50kW to 28 kW
50HZ
45HZ
40HZ
© 2013 Toyota Motor Corporation Australia Limited 15© 2013 Toyota Motor Corporation Australia Limited 15
Case Study: VSD Drives - Results
After Kaizen – 2 X Exhaust Fan:
• Reduced frequency from 50 Hz to 45 Hz and then 40 Hz
• Power reduction from 17 kW to 9 kW
50HZ
45HZ
40HZ
© 2013 Toyota Motor Corporation Australia Limited 16© 2013 Toyota Motor Corporation Australia Limited 16
Case Study: VSD Drives - Results
After Kaizen:
• Power savings: $23,294• Gas savings: $28,071 (reduced air flow)• Maintenance: $2,128 (no need to repair the
belts & pulleys on a regular basis)• Equipment parts cost savings: $3,950
(motors are now ramped up slowly resulting in less stress on belts and pulleys)
• Total savings: $57,443 per year• Implementation cost: $34,700• Pay back 7 Months
© 2013 Toyota Motor Corporation Australia Limited 17© 2013 Toyota Motor Corporation Australia Limited 17
Case Study: VSD Drives - Yokoten
Yokoten and Next steps:
• Roll out activity to other fan motors across the Paint Shop
• Identify potential applications in other shops such as:
• Black Out Spray Booth Paint Shop• Torit exhaust system in Body Shop• Weld exhaust system in Press Shop• Emission test Laboratory ventilation
system
© 2013 Toyota Motor Corporation Australia Limited 18© 2013 Toyota Motor Corporation Australia Limited 18
Case Study: VSD Drives – Recognition
TMCA acknowledges that the key knowledge about process improvements sits in the TEMS work teams and we hold an annual awards process to recognise their efforts.•In 2013 there were 10 teams competing in the annual TEMS awards•The combined savings of the projects put forward exceeded $1.4 million per year•The 2013 Winner and submission for the Global Eco Award was the Paint Shop Maintenance VSD Drive project