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Drug Plastics & Glass Company, Inc. Oxford, Indiana

Drug Plastics & Glass Company, Inc. Oxford, Indiana. Advancing Manufacturing Summit VIII: The Economic and Environmental Benefits of Sustainable Manufacturing Wednesday March 25, 2009 Purdue University – West Lafayette, Indiana. TAP (WIRE) TIME LINE. Sign on to TAP (WIRE) program (Oct 07)

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Drug Plastics & Glass Company, Inc. Oxford, Indiana

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  1. Drug Plastics & Glass Company, Inc.Oxford, Indiana Advancing Manufacturing Summit VIII:The Economic and Environmental Benefits of Sustainable Manufacturing Wednesday March 25, 2009Purdue University – West Lafayette, Indiana

  2. TAP (WIRE) TIME LINE • Sign on to TAP (WIRE) program (Oct 07) • Initial TAP Plant Visit/Assessment (Nov 07) • Plant Energy Team Formed (Nov 07) • Metrics for Success (Dec 07) • WIRE Energy Training (07 & 08) • Implementation of Best Practices (07 & 08) • Control & Sustainment (08 & Beyond)

  3. PROGRAM RESULT ANNUAL SAVING IN 2008 = $101,180

  4. ENERGY COST SAVING INITIATIVES • AIR COMPRESSORS • VFD (CHILLED & TOWER WATER) • LIGHTING (T-5 FIXTURES) • HVAC • MOTORS • MATERIAL HANDLING • WASTE REDUCTION (RECYCLING)

  5. AIR COMPRESSORS • Audit for air leaks on monthly schedule • Replaced air cooled compressors with water cooled units • Purchased air sequencer • Adopted pro-active & predictive maintenance program • Replaced bad piping • BEFORE = 7 ATLAS AIR COOLED TOTAL 310 HP • Maximum Output • NOW = 2 KAISERS WATER COOLED - 175 HP

  6. LIGHTING (HID VS T-5) REPLACED 105 HIGH BAY LAMPS WITH T-5 FIXTURES

  7. HVAC (Moisture On Roof)IR Camera

  8. PREMIUM VS STANDARD EFFICIENCY MOTORS

  9. WHAT WE LEARNED • OVERCOMING THE SKEPTICS • SIX SIGMA APPROACH (DATA DRIVEN) • TRAINING & MORE TRAINING • PLANNING & EXECUTION • MEASURE TWICE CUT ONCE • GET THE RIGHT PEOPLE ON THE TEAM • CONTROL & SUSTAIN • INVOLVE HOURLY PERSONNEL • CONTINOUS TRAINING & IMPROVEMENT • DEVELOP A SYSTEM OF SELF AUDIT • ENERGY METRICS

  10. QUESTIONS? THANK YOU…..

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