Lean & Energy Toolkit: Contents & Acknowledgements
Table of Contents:
- Executive Summary
- Preface
- Chapter 1 Introduction
- Chapter 2 Integrating Lean, Energy Efficiency and Greenhouse Gas Management
- Chapter 3 Overview of Energy Use and Lean
- Chapter 4 Energy and Greenhouse Gas Assessment Strategies
- Chapter 5 Energy and Greenhouse Gas Emission Reduction Tools and Strategies
- Conduct Energy Kaizen Events
- Use Total Productive Maintenance to Reduce Equipment Energy Waste
- Replace Over-Sized and Inefficient Equipment with Right-Sized Equipment
- Design Plant Layout to Improve Flow and Reduce Energy Use
- Encourage Energy Efficiency with Standard Work, Visual Controls, Employee Engagement and Mistake-Proofing
- Reduce Greenhouse Gas Emissions through Transportation Efficiencies
- Chapter 6 Conclusion
- Appendix A: Energy and Greenhouse Gas Management Service Providers, Resources, and Tools
- Appendix B: Sector-Focused Energy Reduction and Greenhouse Gas Management Resources
- Appendix C: Energy Conversion Resources and Rules of Thumb for Estimating Energy Cost Savings
Boxes:
- Example Results from Lean and Energy Improvement Efforts (Box 1)
- Benefits of Coordinating Lean, Energy and Greenhouse Gas Management (Box 2)
- Lean and Energy Use Reduction: Company Cost Savings Experience (Box 3)
- Lean and Energy at Toyota (Box 4)
- Why Be Strategic About Energy Management (Box 5)
- Energy End Uses: What Do We Use Energy To Do? (Box 6)
- Questions for Understanding Energy Use (Box 7)
- Energy Treasure Hunts at General Electric (Box 8)
- Energy Savings (Box 9)
- Common Energy Units (Box 10)
- Example Results from Value and Energy Stream Mapping Projects (Box 11)
- Six Sigma and Energy Savings at Baxter International (Box 12)
- What Is An Energy Kaizen Event (Box 13)
- What Is TPM? (Box 14)
- Strategies for Integrating Energy Reduction Efforts Into TPM (Box 15)
- Energy Reduction Checklist for Combustion, Steam Generation, and Process Heating Systems (Box 16)
- Over-Sized Equipment (Box 17)
- Three Ways to Right-Size Your Fan System (Box 18)
- Flow and Energy Use (Box 19)
- UPS: Fuel Efficiency Through Fleet Optimization (Box 20)
- Ways to Reduce Your Employees’ Commutes (Box 21)
Figures:
- ENERGY STAR Guidelines for Energy Management (Figure 1)
- Sources of Energy Used for U.S. Industry and Manufacturing, 2005 (Figure 2)
- Example Value Stream Map (Figure 3)
- Example Process Data Box with Energy Use Data (Figure 4)
- Example Visual Control (Figure 5)
- Dashboard Visual Controls (Figure 6)
- Materials Used by Cummins in Employee Engagement Energy-Reduction Efforts (Figure 7)
- Fuel Used for Transportation (Figure 8)
Tables:
- Energy Use Hidden in Lean Wastes (Table 1)
- Top Ten Energy Reduction Recommendations (Table 2)
- Example Actions Identified at a Kaizen Event (Table 3)
- Example Energy Use Checklist (Table 4)
Acknowledgements
The U.S. Environmental Protection Agency (EPA) is grateful for the invaluable assistance of the organizations and individuals who helped develop this toolkit and shared experiences, tools, and techniques for integrating Lean manufacturing and energy management efforts.
EPA’s Lean and energy partners include Baxter International, California Manufacturing Technology Consulting (CMTC), Eastman Kodak Corporation, Eaton Corporation, General Electric (GE), HNI Corporation, the National Institute of Standards and Technology (NIST) Manufacturing Extension Partnership (MEP), The Pew Center on Global Climate Change, and the U.S. Department of Energy. EPA’s Office of Policy and the Office of Chemical Safety and Pollution Prevention participated in the development of this toolkit.
In addition to these organizational partners, this toolkit has benefited from the collective expertise and ideas of many individuals. In particular, EPA would like to thank the following individuals for their thoughtful contributions:
- Susan Boone, Lean Six Sigma Trainer, GE Infrastructure
- James Breeze, Energy Engineer/Project Leader, Worldwide Energy Office, Eastman Kodak Company
- Jenni Cawein, Corporate Environmental Health and Safety (EHS) Engineering Manager, Baxter International
- Gerald Church, Director of Energy Services, CMTC
- Rob Currie, Director, Corporate EHS Engineering, Baxter International
- Michelle Gaither, Technical Research Coordinator, Pacific Northwest Pollution Prevention Resource Center
- Gretchen Hancock, Project Manager, GE Corporate Environmental Programs
- Ernie Kulik, Corporate EHS, Eaton Corporation
- Scott Lesnet, Member EHS Manager, HNI Corporation
- Mike Molnar, Sustainability Manager, Cummins, Inc.
- Kirk Prather, Operations Manager Energy Services, CMTC
- Douglas W. Prihar, Management Assistance Partnership Project Director, Nevada System of Higher Education
- Randy Shultz, Facilities and EHS Manager, Eaton Truck, Shenandoah, Iowa
- Ken Somers, Senior Expert, McKinsey Corporation
- Scott Summers, Director and Vice President, EHS, Film Products Group, Eastman Kodak Company
- Carroll Thomas, Partnership Catalyst, NIST MEP
- Walt Tunnessen, National Program Manager, ENERGY STAR
- Sarah Wendel, The Monterey Institute of International Studies
- Joe Wolfsberger, Vice President of Corporate EHS, Eaton Corporation
This toolkit was prepared for the U.S. Environmental Protection Agency by Ross & Associates Environmental Consulting, Ltd. (http://www.ross-assoc.com) in association with Industrial Economics, Inc. (EPA Contract # EP-W-04-023).