The Lean Laboratory

Peter James, S-Lab (Safe, Successful, Sustainable Laboratories)

www.goodcampus.orgwww.effectivelab.org.uk

About UsLinking key laboratory stakeholders- e.g. researchers, lecturers, technical support, estates, designers & suppliers Enabling strategic discussion of lab design, management and operation- identifying and driving improvement Conference and workshops Awards scheme Good practice advice/publications Audit and assessment tools

2012 Award Winners

Imperial – Continuous Commissioning Liverpool – Central Teaching Laboratory Loughborough – Kit Catalogue Oldham 6th Form College – Regional Science Centre Mike Foulkes/Plymouth – ISO 9001 Sheffield Hallam – Cell Culture Lab St Andrews – Chemistry Teaching Andrea Sella/UCL – Water Efficiency

Why Labs Will Change

Core to STEM institutions Financial pressures Student/staff expectations Regulatory/stakeholder demands Evident inefficiencies More good practice examples Developing capability/confidence

The Conference View

Is there scope to significantly increase the efficiency and effectiveness of labs, without compromising quality of work or safety?- 66% said great scope- 30% said some scope What would most help to achieve this?- more pressure from funders (60%)- more focus by senior staff (57%)- more cross-functional working (54%)

University of Liverpool- Central Teaching Laboratory

University of St Andrews- Chemistry Teaching Lab

Imperial College- Continuous Commissioning

The Lab as a Business

A 10,000 m3 + successful laboratory- £30 million + income streams A building cost of £25-30 million Equipment assets of £5-10 million Operating costs of £15-20 million Space costs of £300+ per m2

Utilities £500,000 + Materials/consumables £500,000+ Are assets and resources used effectively? Are they understood?

Lab Energy CostsLab Audited GIA/m2 Electricity

cost £Gas cost £

Total Energy Cost £

Liverpool - Bioscience

7,750 247,000 60,000 307,000

Edinburgh – Cancer Research

3,000 152,000 48,000 200,000

York - Biology 12,740 373,000 102,000 475,000

Manchester - Chemistry

3,816 432,000 161,000 593,000

Cambridge - Chemistry

27,603 888,000 211,000 1,099,000

Lab Energy Split (£)

Bioscience Chemistry

Ventilation (including related heating)

45 60

Equipment 25 15

Conventional Heating/Hot Water

20 20

Lighting 10 5

Freezer Energy Varies Model Capacity

(litres)Cost per

litre (£)Annual running

cost at 7.3p/kWh

New Brunswick (Green model)

570 0.54 £306

New Brunswick  (Green) 570 0.55 £314New Brunswick  (Green) 570 0.57 £326Van der Woude Revco 570 0.76 £434

Lab Impex Research 570 0.85 £487

Heraeus 691 0.93 £641Illshun DF8517 484 1.12 £541Kaye Sanyo  MDF-U70V  728 1.13 £824

New Brunswick 101 1.79 £180

Case 2 – Better Chemical Management, Edinburgh

Tracking all chemicals through barcoded containers

Users see in-house inventory when ordering

£100,000 first year savings of chemical purchasing costs

£12,000/year savings of management/disposal costs

Fast access to chemicals Regular chemical auditsSciQuest e-procurement links

Derek Burgess, Procurement Manager

Lean Lab Principles – Equipment and Resources

Making issues visible Addressing root causes Right sizing Adjusting to needs Optimal efficiency High utilisation Effective management & communication Rich information

Leaner Cold Storage

Making issues visible, e.g. - total cost (incl space, heat load)- compromised performance- reporting/monitoring requirements Addressing root causes, e.g.- storing unwanted samples- overly high storage temperatures- lack of ownership Right sizing- based on actual storage needs- standardised eqt sizes/procurement

Leaner Cold Storage

Adjusting to needs- appropriate temperatures (storage policy)- filling/blanking empty space- modular spaces Optimal efficiency- regular maintenance- cool locations- buying high efficiency models- chest rather than upright- larger models

Leaner Cold Storage High utilisation- optimised containers & racking- central services- shelf/area allocation Management and communication- cross-functional approach- clear responsibilities- policies (storage, procurement etc)- incentives (shared savings) Rich information- inventory management (expiry)- individual bar coding

Leaner Chemicals Making issues visible- total costs (incl storage & disposal)- waiting times- reporting/security requirements Addressing root causes- nasty chemicals, why?- concerns about purity Right sizing- smaller containers Adjusting to needs- microscale experiments Optimal efficiency

Leaner Chemicals

High utilisation- tracking amounts & locations Effective management & communication- policies- shared savings Rich information- computerised database

Building & Services ActivitiesSupply

Design & Management

Voltage optimisation/reductionHigh efficiency transformersHigh efficiency back upZero/low carbon sourcesThermal recovery/storage

Fabric & lighting (LED)Wider operating parametersEfficient/modular equipmentLow flow/alternative containmentDemand responsivenessFree cooling/heating

High efficiency equipmentEqt consolidation/sharingLay out & zoningStorage policies/actionsCentral servicesSpace efficient/natural write up

Good understandingEffective maintenanceMonitoring/recommissioningRight sizingEnergy awareness/incentives

Laboratory Energy Opportunities

Biosciences – Big Energy Users

•Freezers (-20 and -80) •Controlled environmental chambers•Water baths•Incubators•Ovens•Icemakers•Hybridisers•Autoclaves•Mass spectrometers•Laser microscopes

Chemistry – Big Energy Users

•Hotplates/heater-stirrers•Mass spectrometers•Gas chromatography•Rotary evaporators•NMRs•Ovens•Fridges•Pumps•Water baths

Liverpool Bioscience- Equipment

Equipment Typical peak rated power (W)

Energy use per unit (kWh/year)

Total energy use (kWh/year)

Costs (£/year)

Freezer (-20) 1,000 4380 249,660 19,973Envtal chamber 1500-2500 8760 105,120 8,410

Water bath 500 – 1500 3276 101,556 8,124

Incubator 850 3723 89,352 7,148Freezer (-80) 1,200 5256 73,584 5,887Oven 1,500 4336.2 47,698 3,816Ice maker 2,400 10512 31,536 2,523Hybridiser 750 3285 19,710 1,577Incubator-shaker 1,500 2592 18,144 1,452Thermal Cycler (PCR)

250-1600 288 9,504 760

Equipment Energy Varies

kWh

Annual running

cost @7.3p/kWh

Trimat 2 (Ducted) 0.44 £281.37ESCO ACZ 4D1

(recirculating) 0.33 £211.03

Growth Cabinet kWh

Annual Running

CostSanyo Fitotron 20.64 £549Percival small 26.90 £716 Percival scientific 36.36 £968Sanyo 2 62.0 £1,814 Conviron 92.85 £2,711

Growth Cabinet Biological Safety Cabinet

-80 Freezer Costs

Data supplied by University of Newcastle

0

10

20

30

40

50

60

70

570L 725L 585L 760L

Dai

ly E

ner

gy

Use

(kW

h)

Capacity (L)

Min

Ave

Max

For 725L freezer:Energy ranged from 6,000–21,000 kWh/y

Costs ranged from ~£500 - £1800/y

Difference = £1300/y PER FREEZER!

Procure Energy Efficient FreezersEnergy Star label for Lab Grade freezers

-80 Freezer Costs

Case 5 – ReplacingFreezers at Newcastle

£725 litre freezer energy- 6,000–21,000 kWh/y

£180,000 of central funding to replace old models

36 -80 freezers replaced, saving 131,000 kWh

7 years, at 9.5p per kWhReduced space, more reliableMore £ for research

Clare Rogers, Director Estates Support Services

Case 4 – Improved Sample Tracking, Queen Mary

Blizard Institute Cell & Molecular ScienceCombined 8 research centres, 40 liquid

nitrogen dewars into centralised storeBarcode tracking & standardised containers50% fewer samplesEasier sample retrievalLess degradation riskHuman Tissues Act

compliance easier

Lab Assessment

•Self-assessment tool for lab users (and estates)•Inspired by work of LabRATS•Building (high level) and Lab Specific Assessment templates•Lab specific assessment – 30 criteria in 9 categories•Evidence of compliance•Best practice guidance•2-3 hrs per lab

Lab Assessment categories

Ambient conditions & ventilation

Chemicals and materials

Cold storage

Fume cupboards

Lighting

Scientific equipment

Waste & recycling

Water

Innovation