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The Lean Laboratory

The Lean Laboratory. Peter James, S-Lab (Safe, Successful, Sustainable Laboratories) www.goodcampus.org www.effectivelab.org.uk. About Us. Linking key laboratory stakeholders - e.g. researchers, lecturers, technical support, estates, designers & suppliers

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The Lean Laboratory

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  1. The Lean Laboratory Peter James, S-Lab (Safe, Successful, Sustainable Laboratories) www.goodcampus.org www.effectivelab.org.uk

  2. About Us Linking 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

  3. 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

  4. 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

  5. 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%)

  6. University of Liverpool- Central Teaching Laboratory

  7. University of St Andrews- Chemistry Teaching Lab

  8. Imperial College- Continuous Commissioning

  9. 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?

  10. Lab Energy Costs

  11. Lab Energy Split (£)

  12. Freezer Energy Varies

  13. 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 audits SciQueste-procurement links Derek Burgess, Procurement Manager

  14. 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

  15. 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

  16. 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

  17. 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

  18. 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

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

  20. Laboratory Energy Opportunities Fabric & lighting (LED) Wider operating parameters Efficient/modular equipment Low flow/alternative containment Demand responsiveness Free cooling/heating High efficiency equipment Eqt consolidation/sharing Lay out & zoning Storage policies/actions Central services Space efficient/natural write up Building & Services Supply Activities Good understanding Effective maintenance Monitoring/recommissioning Right sizing Energy awareness/incentives Voltage optimisation/reduction High efficiency transformers High efficiency back up Zero/low carbon sources Thermal recovery/storage Design & Management

  21. Biosciences – Big Energy Users Freezers (-20 and -80) Controlled environmental chambers Water baths Incubators Ovens Icemakers Hybridisers Autoclaves Mass spectrometers Laser microscopes

  22. Chemistry – Big Energy Users Hotplates/heater-stirrers Mass spectrometers Gas chromatography Rotary evaporators NMRs Ovens Fridges Pumps Water baths

  23. Liverpool Bioscience- Equipment

  24. Equipment Energy Varies Biological Safety Cabinet Growth Cabinet

  25. -80 Freezer Costs Data supplied by University of Newcastle

  26. -80 Freezer Costs 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 Freezers Energy Star label for Lab Grade freezers

  27. 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 kWh Reduced space, more reliable More £ for research Clare Rogers, Director Estates Support Services

  28. Case 4 – Improved Sample Tracking, Queen Mary Blizard Institute Cell & Molecular Science Combined 8 research centres, 40 liquid nitrogen dewars into centralised store Barcode tracking & standardised containers 50% fewer samples Easier sample retrieval Less degradation risk Human Tissues Actcompliance easier

  29. 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

  30. Lab Assessment categories Ambient conditions & ventilation Chemicals and materials Cold storage Fume cupboards Lighting Scientific equipment Waste & recycling Water Innovation

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