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Toyota Energy Team
E M O
Toyota’s Energy Toyota’s Energy ProgramProgram
NAEM P t ti M 4 2010NAEM P t ti M 4 2010
ProgramProgramNAEM Presentation: May 4, 2010NAEM Presentation: May 4, 2010
Bruce Bremer Bruce Bremer -- Manager Facility Engineering:Manager Facility Engineering:email: email: [email protected]@tema.toyota.com
Toyota Motor Engineering & Manufacturing North America, Inc.Toyota Motor Engineering & Manufacturing North America, Inc.
11
Who are we?Who are we?Who are we? Who are we?
7 Assembly Plants, 3 Engine Plants, 4 Unit 7 Assembly Plants, 3 Engine Plants, 4 Unit Plants R&D Plants Office SpacePlants R&D Plants Office SpacePlants, R&D Plants, Office SpacePlants, R&D Plants, Office SpaceOver 30,000 employeesOver 30,000 employeesPl t 30 Milli S F tPl t 30 Milli S F tPlant space 30 Million Square FeetPlant space 30 Million Square Feet
22
Manufacturing in North AmericaManufacturing in North America
CAPTIN 1985
TMMC 1988
TEMA1996 TMMWVTMMI
SIA 2007
TMMC 2 2008
TABC 1971
TMMK1988BODINE
1990
19981999
BODINE2005 TMMAL
2003TMMBC 2004
TMMTX 2006
2005
TMMMS
33
2006
Toyota’s Environmental Vision Toyota’s Environmental Vision yy“To become the most admired and respected
t bil f t b d t tiautomobile manufacturer by demonstrating continuous environmental performance improvements
resulting in environmental leadership andresulting in environmental leadership and sustainability.”
44
Contributing to a Prosperous Low Contributing to a Prosperous Low C b S i t Th h S t i bilitC b S i t Th h S t i bilitCarbon Society Through SustainabilityCarbon Society Through Sustainability
Sustainable Mobility: Environment, Sustainable Mobility: Environment, Safety & Traffic Congestion, InnovationSafety & Traffic Congestion, InnovationPlant Initiatives: Energy Reduction, Plant Initiatives: Energy Reduction, Kaizens and ConversionKaizens and ConversionS S SS S SSustainable Society: Skills, Expertise Sustainable Society: Skills, Expertise through Business Activitiesthrough Business Activities
55
Energy Sustainable Plant InitiativesEnergy Sustainable Plant Initiatives“a plant that fully utilizes natural resources while operating
in harmony with the environment
Energy Reduction① Development/introduction of & low CO2
Energy Reduction① Development/introduction of & low CO2 p
production technologies ② Daily kaizen activities
pproduction technologies
② Daily kaizen activities② y
Energy Conversion③ Utili ti f bl ( l t )
② y
Energy Conversion③ Utili ti f bl ( l t )③ Utilization of renewable energy (solar, etc.)③ Utilization of renewable energy (solar, etc.)
66
Increase Employee Environmental Awareness
Toyota Drivers for EnergyToyota Drivers for EnergyToyota Drivers for Energy Toyota Drivers for Energy ReductionReduction
Company Earth CharterCompany Earth CharterCompany Earth CharterCompany Earth CharterCost Reduction OpportunitiesCost Reduction OpportunitiesCompany KPICompany KPICompany KPICompany KPIRight Thing To DoRight Thing To Do
77
Energy FootprintEnergy Footprint
What is the Energy Life Cycle of our Product?What is the Energy Life Cycle of our Product?
Manufacturing:Production &Production & Transportation
Parts Suppliers: Production &
Consumer:Use &
Transportation End of Life
88Reduce CO2 in all Aspects of our ProductReduce CO2 in all Aspects of our Product
CO2 ProfileCO2 Profile
1000
Manufacturing OnlyMTons*1000 CO2
800
1000
600
400
0
200
99
0Stationary
GasPurchasedElectricity
MobileLogistics
TravelCommuting
Energy/CO2 Consumption Energy/CO2 Consumption gy pgy p
Natural Gas24%
Electric46% Electric
Natural Gas54%
76%54%
CO2 EmissionsEnergy Usage
1010
Electricity is the main source of CO2 emissions
Energy Consumption Per UnitEnergy Consumption Per Unitgy pgy p
102009
Production D d
6
8Decreased over 30%
4
6
MMBtu/veh
0
2
2001 2003 2005 2007 2009
23% (12% 2009) Energy Reduction
FY
1111
23% (12% 2009) Energy Reduction 20% CO2 Reduction
Aim:Aim:--Minimize Minimize
Green, Lean and CleanGreen, Lean and CleanTowards the UltimateTowards the Ultimate
Ultimate ECO EmissionsEmissions
Towards the UltimateTowards the UltimateECO FactoryECO Factory
ECOFactory
Integrated Energy Policy
New Plant Design Concept
Integrated Energy Policy
Integrated Equipment/ Building Design On-Site Generation
Reduce
g g
Reclaim Waste Heat
CO Focus
Co-generation
Purchase
CO2 Capture/Store
EnergyEnergy EnergyEnergy AlternativeAlternative Carbon
Reduce Operations Use
CO2 Focus KPI
Purchase Contract
Sequestration
1212
Energy Energy ReductionReduction
Energy Energy ConversionConversion
Alternative Alternative EnergyEnergy
CarbonOffset
Energy Program KeyEnergy Program Key ElementsElements
Targets
Toyota Energy Team
E M O ProcurementContracts
Senior Mgmt Support
Targets
Awards & Recognition
Supply Reliability
Contracts
pp
KPI Bench-marking
RecognitionKaizens
TPS
OrganizationVisualization & reporting T/M
Support Energy Minimization
TPS
Measuring Implementation Plans
Minimization
External Groups
1313
GroupsTreasure
HuntPilot
Projects
Key Performance IndicatorsKey Performance IndicatorsKey Performance IndicatorsKey Performance Indicators
Energy & WaterEnergy & Water CompanyCompanyEnergy & WaterEnergy & Water--Company Company Environmental KPIsEnvironmental KPIsR i t ll l l f thR i t ll l l f thReview at all levels of the Review at all levels of the organizationorganization
Cost QualityT/M
Development
E i t l Risk/Safety
yDevelopment
1414
Environmental Risk/Safety
Energy Management Energy Management Organization (EMO)Organization (EMO)Organization (EMO)Organization (EMO)
EMO Responsibilities:EMO Responsibilities:--KaizensKaizens --WindowWindow
Corp Facility Manager
Corp. President
Plant
--Kaizens Kaizens --WindowWindow--Budgets Budgets --TargetsTargets--Reports Reports --UpdatesUpdates
CommunicationsCommunications Corp. Facility Manager
Other PlantsEnvironmental Steering Committee
Facility Manager
PlantPresident
--CommunicationsCommunications
CommitteeFacility EMO Leader
PaintShop Captain
PlasticsShop Captain
WeldShop Captain
FacilitiesShop Captain
PressShop Captain
AssemblyShop Captain
1515
Company Wide Energy ProgramCompany Wide Energy Program
Energy Measuring SystemEnergy Measuring System
To Manage it you need to To Manage it you need to
O C O S O
g yg ybe able to Measure it!be able to Measure it!
3. Production Energy Consumption
1. Received Volume 2. Produced & supplyVolume
FACILITIES PRODUCTION SHOPUTILITY CO.
Sit UtilitiP i Site Utilities Production areaPrimary energy
1616
Energy Target SettingEnergy Target Setting
Purpose :
Become the North American Leader (#1) in energy usage per vehicle
among all North American Automobile Manufacturing Facilities
Energy Metering : All shop metering is operational and meets TMC's requirements.
Develop plan and implementation costs for measuring all utilities ED, Primer, T/C Booths, and all Ovens by the end of November 2002.
Kaizen Scenarios:
2008 Energy Action Plan
among all North American Automobile Manufacturing Facilities.
Current Situation
FY '02 Energy Usage7.9
5.66.3
6.7
5.0
6.4
5.3 5.06.0
9.0
Veh
NAMC CurrentMother Plant CurrentNAMC Revised Goal
Assy 2006 Target
Kaizen Scenarios: TMMI $/MMBTU = 6.49$ (US) Energy Savings Savings Implement. Impl.
Operational Kaizens Dept. (MMBtus/Veh) ($)/Veh $/Veh Costs ($)A. Reduce NAMC electrical loads to TMC BS and WE stds; All 0.56 3.63$ 0.29$ 50,000$ Tahara BS=30 WE=12, TMMI Current BS=66 WE = 37B. Reduce painting booth air flow IAW NFPA 91. 10% T/R 0.18 1.19$ 0.12$ 20,000$ reduction from existing 1,266,250 cfm.C. Eliminate air flow in portions of paint booths that work T/R 0.14 0.93$ 0.29$ 50,000$ is not being performed in. Reduce booth area 3% average.D. Reduce air volume at lunch and between shifts to 50% of T/R 0.05 0.36$ 0.12$ 20,000$ 1 033 000 f T t l f 4 7 h d (G S i )
Energy Usage
4.4
2.6 2.6
5.05 3 5 04.7
4.6
4.7
0.0
3.0
Plant 1 Plant 2 Plant 3 Plant 4 Comp. Average
MM
Btu
/V
Best Plant '06
1,033,000 cfm. Total of 4.7 hours day. (Gas Savings)E. Database Kaizens not yet implemented All 0.29 1.88$ 3.17$ 550,000$
Sub-Total 1.23 7.99 3.97$ 690,000$
Major Kaizens1. Steam Generation through Incinerator Waste Heat T 0.22 1.42$ 5.76$ 1,000,000$ Recovery: 6 klb/hour 60 psi steam2. EnergySaver panels: 2,000 HIDs, 24 x 365 and 100T ALL 0.03 0.17$ 6.33$ 1,100,000$
baseload cooling 8 months ear
- Investigate and Plan Operational kaizens by 3rd Qtr FY04- Evaluate Major kaizen budget in 4th Qtr of FY04
Energy Usage
0.30
0.34
4 14
0.24
0.96
0.34Paint Plastics
Weld Other
Ass'y Stamp
Total MMBtu/Veh
6.32
baseload cooling 8 months year2. Add De-Superheater: Recover heat from ACU for F/C 0.02 0.14$ 0.58 100,000$ pre-heating boiler water make-up water.
Sub-Total 0.27 1.73 12.66$ 2,200,000$ Project Payback = 1.71 Total 1.50 9.72 16.63$ 2,890,000$
Energy Reduction
1.230.27
6.90
Veh
Usage/Veh Kaizen Costs Reduction
$7 99$49.00
$56.00
R
Cost/Veh Kaizen
Non-Production Time Energy Usage
4.14
66%
Weekend
Bet. shift37%
12%
% Peak Load Avg. NA Avg TMC Avg
Bet. Shift 66% 30%Weekend 37% 12%
Yearly Energy TargetsPlant FY 01 FY 02 (Base Year) FY 03 FY 04 FY 05 FY 06 Total
Current Plan 3% 3% 3% 3% 12%
6.325.09 4.82
2.30
4.60
Current OperationalKaizens
Major Kaizens
MM
Btu
/V
$51.11
$43.12 $41.39
$7.99
$1.73
$35.00
$42.00
Current OperationalKaizens
Major Kaizens
VC
R
1717
Key Activities:
1) Focus on paint shop energy reductions2) Optimize Non-production energy
Mother plantPlantAdditional Plan 0% 3% 5% 5% 13%New AnnualReduction Targets 3% 6% 8% 8% 25%
Actual Target (MMBtu/Veh) 8.12 6.32 6.130 5.750 5.245 4.739 1.58
- Total Reduction required to achieve target ( FY02 - FY06)
Implementation PlansImplementation Plansto Reach our Targetsto Reach our Targets
Energy Kaizen Database Energy Kaizen Database –– ToolTool10,000 Kaizen ideas10,000 Kaizen ideasOperational projectsOperational projectsp p jp p jCapital projects:1Capital projects:1--3 year payback3 year payback
1818
Kaizen Kaizen Sealer Pumps
CO2
SO2
Nox
Major. Equip. Change CO2/MMBTU
lbs/MMBTU
2.010
117.08
Originator:
NAMC:
Paint Kaizen Team
TMMK Cost Center:
Plant:
Process/Equipment:
Kaizen Type:lbs/kWH
ST900
Paint Date: 10/1/2002
Equipment ModificationOperational
lbs/MWH
502-868-4456
T-0491-0001Kaizen ID # lbs/MWHNAMC ID#:
Plant 2 Shop: Paint Dept:
Phone #:
Electric Utility Emissions Data Gas Emissions
Kaizen Title:Sealer Hydraulic Motor Energy Reduction
Kaiz
en L
ocat
ion
Ori
gina
ting
Loc
atio
n
Detail SheetDetail Sheet Comp. Chilled
Electricity Natural Gas Air Steam Water Water WWT POTW Other
Background/Description: The Sealer area in Paint 2 uses two (2) electric motors to power hydraulic pumps that provide pressurized sealer to the robots. These supply motors run 24 hours/day from Sunday start-up through Saturday shut-down.
Current Situation (Before Kaizen) Projected Situation (After Kaizen)
Res
ourc
e Check all that apply:
Benefits:Benefits:OpportunitiesOpportunities
2 Pumps 1 Pumps60 HP 60 HP
0.746 kWH/HP 0.746 kWH/HP24 Hours day 24 Hours day5 Days/week 5 Days/week
4.2 Weeks/mo 4.2 Weeks/mo12 Months/year 12 Months/year0.6 Load factor 0.8 Load factor51 Amps 24 Amps
S l P 480 V lt S l P 480 V lt
( ) j ( )
Kaiz
en D
escr
iptio
n
--Opportunities Opportunities --Current situationCurrent situation--Proposed kaizenProposed kaizen
Sealer Pumps 480 Volts Sealer Pumps 480 Volts1.7321 1.73211000 W/kWH 1000 W/kWH
Accumulator
Energy Use Before Kaizen (Energy units/yr) Energy Use After Kaizen (Energy Units/yr) Energy Savings(Energy Units/yr)
Non-prod nEnergy units
Gas (MMBtu)
C d Ai (k f)
Electricity (kWh)
113,439.7 -
226,879.5
-
340,319.2
-
Usa
ge60hp60hp 60hp60hp
Proposed kaizen Proposed kaizen --Cost and savingsCost and savings
Implementation Cost $/unit Projected Annual Savings
Engineering Services:
L b d i l f
Steam (klb)
Chilled Water (kton)
Water (kgal)
WWT (kgal)
Compressed Air (kscf)
-
-
-
-
-
-
POTW (kgal)
CO2 (metric tons)
Other: Explain
-
-
303.5
-$ Electricity (kWh)
202.3 101.2
-$ -$
$
-
-
- -
- - - - -
-
-
-
-
Ener
gy/E
NV
U
Easy to shareEasy to share
Material: Labor and material forLabor: Contract contractor installation.Labor: In House
Other:
Other:
Other:
Total:
Correlation Factor: Energy reductions in terms of rate of flow, square feet, time, etc. Simple Payback Period (yrs):Total:
POTW (kgal)
Other: Explain
-$
-$
-$
-$
-$
-$
Water (kgal)
WWT (kgal)
Gas (MMBtu)
Compressed Air (kscf)
Steam (klb)
Chilled Water (kton)
-$ -$ -$ -$
-$
-$
-$
-$ -$ -$
#DIV/0!
2,500.00$
-$
-$
-$
-$
-$
2,500.00$
-$
Cos
t/Sa
ving
sn
1919
Savings = E = Correllating Factor: Input item Project Time Line:Gas =
Water = The correlating factor may be in terms
Correlation = of 1,000 cfm, nozzles, lights, etc.
Select a common characteristic of thesystem of equipment being kaizen'ed.
Energy Reduction A-3. Approval is granted to proceed with this project.President VP GM AGM Coord Shop Mgr Shop Cap Orig
/1,000 cfm415
kGal
113440
0
kWH
MMBTU
/1,000 cfm
0
273.35
0.000.00
kWH
MMBTUkGal
/1,000 cfm
/1,000 cfmCorr
elat
ion
Appr
oval
Treasure HuntsTreasure HuntsTreasure HuntsTreasure Hunts
Assessment of plants energy usageAssessment of plants energy usagep gy gp gy gInternal and Supplier SupportInternal and Supplier SupportTeam Approach: Engineering, maintenance, Team Approach: Engineering, maintenance, pp g g, ,pp g g, ,production and Facility team members production and Facility team members 3 day event to capture opportunities3 day event to capture opportunitiesReport to managementReport to managementImplement projects by plantImplement projects by plant
2020
Treasure Hunt TrainingTreasure Hunt Training
Purpose of Treasure Hunt Tool:Purpose of Treasure Hunt Tool:
Combine knowledge of Combine knowledge of T/Ms (TEMA, Suppliers, T/Ms (TEMA, Suppliers,
Prod & Maintenance)Prod & Maintenance)Go and seeGo and see Identify energy use Identify energy use
in the workplacein the workplace
Conceive new ideas Conceive new ideas and yokoten existingand yokoten existing Increase energy Increase energy
Fi d tFi d t
2121
and yokoten existing and yokoten existing onesones
gygyawarenessawarenessFind ways to saveFind ways to save
Treasure Hunt Process FlowTreasure Hunt Process Flow
Ki k Off & T i Create TH Teams G & S Create Detail
TH Preparation
Kick Off & TrainIntro to TH
Collect Preliminary DataFinalize Agenda
(5-10 Members)Maintenance T/M’sProduction T/M’s
Engineering T/M’s
Go & See:ID Opportunities
Collect DataGrasp Hurdles
Sheets:Estimate SavingsDescribe Kaizen
Justify Implementation
TH Outcomes
Summarize Kaizens:
Individual Savings
ManagementPresentation:
Implementation:Measure Energy Before
Install
Yokoten:Share Company Wide
Energy Database
TH Outcomes
Individual SavingsIndividual Payback
Totals
Highlight Top KaizensImplementation Support
InstallMeasure Energy AfterFinalize Detail Sheet
Energy DatabaseKeep All Ideas
2222
Supplier Energy ProgramSupplier Energy Program
S li S li
Supplier
Supplier Region
Supplier Region
Supplier Region
S li R l ti
Region Region
Supplier RelationsDay to day working
relationship
TEMA
Purchasing
Facilities Engineering
Technical Energy
TEMA
ProductionEngineering
2424
Technical Energy Resource
Pilot ProjectsPilot ProjectsPilot ProjectsPilot Projects
New Technologies: Design and Implement to New Technologies: Design and Implement to Prove a ConceptProve a Concept
Funding & Labor Support from CorporateFunding & Labor Support from CorporateData collection and verificationData collection and verificationSuccessful pilots shared with all PlantsSuccessful pilots shared with all Plants
2525
Pilot Example: Lighting UpgradesPilot Example: Lighting Upgrades
Before KaizenBefore Kaizen--High bay High bay Metal HalideMetal Halide
After KaizenAfter Kaizen--High bay High bay FluorescentFluorescent
2626Saving at one Plant $.5M/yearSaving at one Plant $.5M/year
Pilot Example:Pilot Example:P i Wi d P jP i Wi d P jPaint Window ProjectPaint Window Project
Winter Set .
Air Intake
Burner l
..
Point
BurnerW
et W
all
Ste
am
Hum
id.
CH
W C
oiS
Paint Booth
Summer Set Point
.
.
.
Temp/RH line for Paint
2727
. Quality1300 Metric Tons CO2 per year
I t d ti b d l l ditiI t d ti b d l l diti
Renewable Energy: Example
(Tsutsumi Photovoltaic System: 3/2008 SOP)(Tsutsumi Photovoltaic System: 3/2008 SOP)
Introduction based on local conditions, Introduction based on local conditions, return on investmentreturn on investment
・・Capacity Capacity :: 2,000KW2,000KW・・Capacity Capacity :: 2,000KW2,000KW
(Tsutsumi Photovoltaic System: 3/2008 SOP)(Tsutsumi Photovoltaic System: 3/2008 SOP)
p yp y ,,--Equivalent to the usage of Equivalent to the usage of 500500 homeshomes--Provides Provides 5050%% of assembly electricity,of assembly electricity,
p yp y ,,--Equivalent to the usage of Equivalent to the usage of 500500 homeshomes--Provides Provides 5050%% of assembly electricity,of assembly electricity,
4%4% of total plant electricityof total plant electricity4%4% of total plant electricityof total plant electricity
(Field Test Project on New Photovoltaic Power Generation)(Field Test Project on New Photovoltaic Power Generation)(Field Test Project on New Photovoltaic Power Generation)(Field Test Project on New Photovoltaic Power Generation)
・・Study solar and wind conditions and incentives then Study solar and wind conditions and incentives then investigate installationinvestigate installation
2828
investigate installationinvestigate installation・・Focus on low cost technologies, including installation costFocus on low cost technologies, including installation cost
Energy Visualization andEnergy Visualization andEnergy Visualization and Energy Visualization and Reporting: AccountabilityReporting: Accountability
Monthly/Quarterly/Yearly energy Monthly/Quarterly/Yearly energy comparison report to Managementcomparison report to Management
Plant & ShopPlant & ShopConsumption, C02 & CostConsumption, C02 & CostTrendsTrends--Previous YearPrevious YearAnnual ReportAnnual Report
2929
Action Plan ReportAction Plan Report
15
Cumulat ive Target Cumulat ive ActualM onthly Target M onthly Energy/Veh
10
15
0
5
A M J J A S O N D J F M Y
Water
1 172
cle
1.170.87
1
al /
Veh
ic
3030
0FY '02 Third Quarter FY '09 Third Quarter
Kg
BenchmarkingBenchmarkingBenchmarking Benchmarking
InternalInternal--Toyota plants across the worldToyota plants across the worldExternalExternal-- Other transportation companiesOther transportation companiesExternalExternal-- Other market sectorsOther market sectorsAEE, Energy StarAEE, Energy Star©© & DOE concepts and & DOE concepts and , gy, gy ppbest practices best practices
3131
AwardsAwardsAwardsAwards
--AEE: International Corporate Energy AEE: International Corporate Energy Management Award 2008Management Award 2008
EPA Energy Star Partner of the Year SustainedEPA Energy Star Partner of the Year Sustained
gg
--EPA Energy Star Partner of the Year, Sustained EPA Energy Star Partner of the Year, Sustained Excellence “6 consecutive years”Excellence “6 consecutive years”
3232
Conclusion: Conclusion:
Reduce Energy and CO2 FootprintReduce Energy and CO2 FootprintReduce Energy and CO2 FootprintReduce Energy and CO2 FootprintDevelop new equipment operating methodsDevelop new equipment operating methodsP t bl i t d iP t bl i t d iPromote renewable equipment design Promote renewable equipment design technologiestechnologiesShare new ideas from company to companyShare new ideas from company to companyEnergy programs are never complete, it is Energy programs are never complete, it is continuous improvement!continuous improvement!
3333
Only Use what you Need, When you Need it, Only Use what you Need, When you Need it, In the Amount Needed!In the Amount Needed!In the Amount Needed!In the Amount Needed!
B BB B M F ilit E i iM F ilit E i iBruce Bremer Bruce Bremer -- Manager Facility Engineering:Manager Facility Engineering:email: email: [email protected]@tema.toyota.com
3434Toyota Energy Team
E M O