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TMMK Energy Management Organization

TMMK Energy Management Organization (History). The initial idea to establish an Energy Management Organization, EMO, began at Toyota Motor Manufacturing North America in 1995, fiscal year 1996.The intent was to enhance energy efficiency by using Toyota Production System, TPS, methods, reduce vehicl

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TMMK Energy Management Organization

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    1. TMMK Energy Management Organization Roger L. Wallin, CPMM Assistant Manager Utilities Engineering / Energy Management Toyota Motor Manufacturing Kentucky, INC.

    2. TMMK Energy Management Organization (History) The initial idea to establish an Energy Management Organization, EMO, began at Toyota Motor Manufacturing North America in 1995, fiscal year 1996. The intent was to enhance energy efficiency by using Toyota Production System, TPS, methods, reduce vehicle cost by minimizing energy required for production, and reduce the environmental impact of our operations. 1). TMMNA conducted presentations of this concept to each of the North America Manufacturing Companies, NAMCs, to gain plant consensus, establish baselines, and begin development of the organization. 2). In 1997, fiscal year 1998, the official Energy Management Organization, EMO, was established. Plant energy and water usage results from fiscal year 1997 were used as the baseline to set reduction targets and determine success of the program. 1). TMMNA conducted presentations of this concept to each of the North America Manufacturing Companies, NAMCs, to gain plant consensus, establish baselines, and begin development of the organization. 2). In 1997, fiscal year 1998, the official Energy Management Organization, EMO, was established. Plant energy and water usage results from fiscal year 1997 were used as the baseline to set reduction targets and determine success of the program.

    3. TMMK EMO (Structure)

    4. TMMK EMO (Roles/Responsibilities) Overall management of the plant-wide Energy Management Program. Establish annual plant utility operating budget to meet cost and energy reduction goals. Establish monthly targets for individual shops, all utilities, with plant-wide roll-up. (Generate weekly and monthly usage reports) Conduct monthly meetings with individual shop EMO captains. (Daily interaction) Energy and water targets are included within the shop Environmental Action Plan, EAP. Shops not meeting their monthly targets must report to the Environmental Steering Committee, ESC, at senior level management including the plant president.

    5. TMMK EMO (Roles/Responsibilities) Each shop has a current fiscal year energy and water reduction project tracking plan. Each shop has a rolling five year energy and water reduction plan. Provide engineering support for reduction activity. Provide maintenance and calibration of plant utility flow meters. Manage plant-wide energy reduction activity/projects. Elimination of Centralized Steam Generation Replace/retrofit plant/site lighting (Building, roadway, parking lot, and walkway) HVAC Duty Cycling Green Weekends Treasure Hunts (Energy audits)

    6. TMMK EMO (Energy Reduction Activity/Projects) Elimination of Centralized Steam Generation Steam is used to heat process water, air flow, and humidity control in paint booths Install point of use high efficiency gas-fired boilers (process water) Install natural gas-fired burners in the paint booths (air-flow) Use high pressure water spray for paint booth humidification Replace/retrofit plant lighting (Building, roadway, parking lot, and walkway) Building: replaced metal halide and high pressure sodium fixtures with high intensity T-8 fluorescent fixtures with motion control sensors Roadway/Parking Lot/Walkway: retrofit high pressure sodium fixtures to use compact fluorescent bulbs

    7. TMMK EMO (Energy Reduction Activity/Projects) HVAC Duty Cycling Reprogram plant heating/ventilation/air conditioning units to duty cycle mode (Units previously ran full time during production periods) Use production and non-production temperature set-points Green Weekends Reduce energy and water usage to the lowest possible level. (If it is not required, turn it off) Shut off compressed air (Ability to turn off compressed air by shop/building)

    8. TMMK EMO (Energy Reduction Activity/Projects) Treasure Hunts Focused audit activity to identify energy and water reduction opportunity at the shop/process level. Audits are conducted by teams during production and non-production time periods. Data is collected and detail sheets are generated to estimate savings potential. Cost saving opportunity is summarized and presented to management representatives. (Gain resource support, manpower and financial) Verify, check, results after implementation. Yokoten, share, saving opportunity with other plants/facilities.

    9. TMMK EMO (Management) Create and implement plant-wide energy reduction programs. Create and implement energy reduction programs, themes, and contests. 1). TMMKs Race for the Greenest. (Plant annual energy reduction) 2). Green Weekends. (Non-production energy to the lowest level) 3). Shutdown week President Energy Reduction Award of Excellence. (Semi-annual plant shutdown period, energy to lowest level) 4). Energy reduction kaizen of the quarter and year 5). Treasure Hunt activity. (Focused energy audits in the production and administrative areas) 6). Publish a plant-wide quarterly energy newsletter, TMMK Energy News Source. (Includes energy information, projects, contests, recognition, tips, etc.) Benchmark other NAMCs and external automotive companies. 7). Educate all T/Ms using plant-wide communication methods including: e-mails, daily group leader communications, TMMK Today, internal TV (Headline News, Inside Track, energy slides), etc.Create and implement energy reduction programs, themes, and contests. 1). TMMKs Race for the Greenest. (Plant annual energy reduction) 2). Green Weekends. (Non-production energy to the lowest level) 3). Shutdown week President Energy Reduction Award of Excellence. (Semi-annual plant shutdown period, energy to lowest level) 4). Energy reduction kaizen of the quarter and year 5). Treasure Hunt activity. (Focused energy audits in the production and administrative areas) 6). Publish a plant-wide quarterly energy newsletter, TMMK Energy News Source. (Includes energy information, projects, contests, recognition, tips, etc.) Benchmark other NAMCs and external automotive companies. 7). Educate all T/Ms using plant-wide communication methods including: e-mails, daily group leader communications, TMMK Today, internal TV (Headline News, Inside Track, energy slides), etc.

    10. TMMK EMO (Energy Reduction Theme/Contest) TMMK Race for the Greenest. Focused plant-wide energy reduction contest. TMMKs Race for the Greenest. (Plant-wide annual energy reduction) 1). Uses a point based system. Shops receive points by meeting targets for total energy, electricity, natural gas, compressed air, water, production and non-production time periods, and bonus points for energy reduction kaizen activity.TMMKs Race for the Greenest. (Plant-wide annual energy reduction) 1). Uses a point based system. Shops receive points by meeting targets for total energy, electricity, natural gas, compressed air, water, production and non-production time periods, and bonus points for energy reduction kaizen activity.

    11. TMMK EMO (Education/Communication) Publish a plant-wide quarterly energy newsletter, TMMK Energy News Source. (Includes energy information, projects, contests, recognition, energy reduction tips, etc.)

    12. TMMK EMO (Results)

    13. TMMK EMO (Rising Cost)

    14. TMMK EMO (History) Even though we have continued to reduce our total energy usage per vehicle, the cost of utilities continue to rise.Even though we have continued to reduce our total energy usage per vehicle, the cost of utilities continue to rise.

    15. TMMK EMO (Moving Forward) Sustain energy reduction savings that have been previously implemented. Investigate additional methods/means to reduce. (New technology, process mapping, etc.) Continue to implement reduction projects and activities to help alleviate the rising cost of utilities. 1). Energy costs continue to rise. Even with reduction activity we cannot stay ahead of the curve. 2). Current legislation on carbon emissions, Cap & Trade, will have an even greater negative effect. 1). Energy costs continue to rise. Even with reduction activity we cannot stay ahead of the curve. 2). Current legislation on carbon emissions, Cap & Trade, will have an even greater negative effect.

    16. TMMK EMO (Moving Forward) Moving Forward Energy Management Develop methods to conduct process mapping, establish baselines, reduce, and then sustain reduction activities implemented. Investigate & apply new technology at the process level. Education Educate shop PE groups on new technology and process application. Educate production groups on energy usage control, standards, and TPS methods. Renewable Energy Resource Development Investigate renewable resource options to reduce energy cost and carbon emissions. (Wind, solar, geothermal, biogas, etc.) Seek local resource partners where available/feasible. Seek regional resource partners to support where elements are unavailable locally to scale.

    17. TMMK EMO (Future Structure)

    18. TMMK EMO (Wrap Up) Toyota Motor Manufacturing Kentucky, TMMK, is part of a world-renowned automotive company, Toyota Motor Corporation, which is founded on the principles of continuous improvement and respect for people. As Toyotas largest vehicle manufacturing plant in North America TMMK has been recognized by the U.S. Environmental Protection Agency, EPA, for its commitment to energy efficiency and management of energy consumption. The EPA recognition consists of 5 ENERGY STAR Awards including 1 Partner of the Year award and 4 Sustained Excellence awards. TMMK continues to achieve a national energy efficiency rating within the top twenty-five percent for automobile assembly plants in the U.S. TMMKs successful performance can be attributed to: A structured Energy Management Organization. Strong leadership and commitment to superior energy performance at the executive level.

    19. TMMK EMO (Wrap Up) Ongoing energy and environmental impact reduction plans. Energy reduction education/awareness activity Individual business unit and team member recognition for meeting energy reduction targets. Direct involvement and support of team members at all levels. Structured energy audit activity. Internal and external benchmarking activity. Continuous improvement philosophy. TMMK has a strong commitment to reduce our total energy usage and plant CO2 emissions through the efforts of our Energy Management Organization, team member support, and the strive for continuous improvement. Reduce, Reuse, Recycle. Sustain energy reduction activity that has been implemented. Only use the utility needed, when needed, and in the amount needed.

    20. Thank You. Q & A

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