goodyear global energy- ghg systemsupplierspartnership.org/members_only/2014-09 abdrabou -...

GoodyearIntegrating Continuous

Improvement in Energy/GHG

Aiman Abdrabou, CEM, CSSBB

Global Manager – Energy & GHG

Goodyear Global EHS Sustainability

1Goodyear - A Sustainability Journey

Biography

- Aiman Abdrabou

• Over 15 years in the field of Energy Engineering / Management

• AEE International Award – 2014 Energy Manager of the Year

• Working with Goodyear since 2009 as a Global Manager – Energy & GHG

• Prior to Goodyear, worked with DTE Energy and General Motors

• Responsible for developing and implementing energy and greenhouse gases (GHG)

strategies for 52 Goodyear manufacturing facilities around the world

• Conducted more than 500 energy assessments/audits (industrial and commercial)

• Degrees:

– B.S. Aerospace Engineering,

– M.S. Industrial Engineering

– Masters Engineering Management

• Certifications:

– Certified Six Sigma Black Belt (CSSBB) - American Society for Quality

– Certified Energy Manager (CEM) - Association of Energy Engineers

– Certified Energy Auditor (CEA) - Association of Energy Engineers

– Carbon Reduction Manager (CRM) - Association of Energy Engineers

– Certified Demand Side Management (CDSM) - Association of Energy Engineers

Goodyear - A Sustainability Journey 2

Why is Sustainability Important at Goodyear?

• Global increase in visibility and emphasis on environmental issues

• Consumers expect leading companies to be environmentally responsible

• Sustainability conveys long-term environmental and social impacts, and financial longevity

• Goodyear can better capitalize on its industry-leading environmental record


Tire Consumers’ Expectations

Today’s consumers have high expectations of tire companies:

• Produce tires for nearly every type of personal or commercial

vehicle

• High-quality products with many fuel-efficiency and

performance options

• Cost of products are affordable

• Produce these products while being responsive to global

environmental concerns


Tire Industry Issues

• Highly dependent on fossil fuels– Tire Materials

– Fuels for Transportation

• Concern about the continued availability and cost of fossil fuels as the world

demand increases

• An estimated 4% of the global oil consumption is used to overcome tire

rolling resistance during vehicle use


External Footprint

Tire Use

87%

Internal

Footprint

13%

Tire Mfg

22%

Raw

Materials

74%

Raw Material

Transport 3%

Product

Transport 1%

Tire use (rolling resistance) is the most significant tire footprint contribution

Total Tire Life CO2 Emissions

Integrating Continuous

Improvement in Energy/GHG

DMAIC Methodology


Based on Jack Simpson “Systems Alive” 2000

Requirement

Champion/Leader

System Resources (Teams)

System Design/ Process Documentation

Certification/Training

Commitment

Corrective Action / Plan

Accountability/Consequences

Feedback

Global Energy System Components


Integrating Continuous Improvement in Energy/GHG

– Six Sigma DMAIC Methodology Overview


Objective and Goals• Energy/GHG Intensity Reduction Indicators

• Energy /GHG Savings Indicators

Define (D): Identify Energy/GHG Opportunities• Plant Energy Coordinator and BC Energy Champions will identifyfeasible energy initiatives to achieve the plant’s energy goal.

•Energy champions will work with their energy teams to develop the detailed description and perform the data collection of the identified initiatives.

Measure (M): Quantify Energy/GHG Savings•Plant Energy Coordinator and BC Energy Champions will use the collected data to perform saving calculations of the energy/GHG opportunities.

• Opportunities should be prioritized based on Simple Payback (SPB) and/or ROI.

•The energy project’s cost, duration, owners should be determined in this phase.

Analyze (A): Develop Action Plan •BC Energy Champions will develop a plan to execute the selected energy/GHG opportunities for the current year.

•Action plans should include project description, owner(s), due date, savings, cost and SPB/ROI

Improve (I): Implement Action Plan•Plant Energy Coordinator and BC Energy Champions to implement the approved action plan.

•Implementation status of energy initiatives will be documented and reported on a monthly basis to the plants (EPM) and to region using CI Tracker.

Control (C): Monitor Energy program•Energy Performance Metric (EPM) Board will be used to track each BC’s energy performance and get the plant leadership support.

•RSEnergyMetrix Monitoring System to be used to track the plants’ energy performance using energy charts and trends.

•Plants will update monthly actual energy savings in CI tracker and add the new energy initiatives.

•Report progress during NAT Monthly Conf Call/WebEx

• Energy Scorecard submitted monthly to the region

Global and Regional Energy/GHG

- Support Structure

Global Manager works with Regional Energy Manager on energy / GHG programs

Goodyear has a Regional Energy/GHG Manager for each region (SBU)

Plants are supported by the Regional Energy Manager to achieve the indicators

Each plant receives multiple energy plant visits every year to drive the strategy

These visits are intended to help in the following:

Drive the strategy in the plants to achieve the indicator and CI saving goals

Share common energy best practices among plants

Provide technical assistance to the plant energy teams

Work with the BC energy champions on executing the BC energy action items

Help the plant to seek opportunities to secure government, state and utility

energy grants and rebates


Plant Energy Coordinators/Manager:

Roles and Responsibilities

Expectations from Certified Energy Managers:

Own the energy initiatives in the plant is a primary role

Identifying and calculating energy savings is important to help prioritize

and select the appropriate energy initiatives

Lead the BC energy champions and execute energy initiatives

Provide technical assistance to the energy champions that are not CEMs

Follow up with the energy champions in each business center

Run progress meeting with the energy champions in each department

Run a monthly meeting at the energy board (EPM) with plant leadership

and the energy team to discuss progress and align priorities


Certified Energy Manager (CEM):

AEE in-house training program


Goodyear has approximately 30 associates that are recognized

as a Certified Energy Managers (CEMs) accredited by the

Association of Energy Engineers (AEE)

Goodyear conducted many AEE in-house training sessions to

certify the plant energy manager to become CEM

North America (NA) & Latin America (LA) teams conducted in

Cleveland in 2010 (22 associates)

Asia Pacific (AP) region conducted in China in 2012 (11 associates)

NA & LA teams conducted in Cleveland in 2013 (6 associates)

Global conducted in Goodyear HQ in Akron, OH in 2014 (3

associates)

Developed Global Lighting Standards:

Training for Indoor Lighting Design

Lighting Level: Comply with the global lighting

standards lighting level in each area

Lighting Technology: Select the lighting technology

that achieves a power density of 0.8-1.0 Watt/SQFT

Lighting Scoring (Twice a year):

Energy Dashboard and Scoring is detailed in the NA

lighting specifications

Team training was conducted to certify each energy

coordinator in lighting design



Best of the Best - Americana Energy Team

- Energy Conservation Internal Committee (CICE)

Operational Team :Machine operators, Mechanics, Electricians, Power House Operators, Quality Monitor,

Safety Technician, Chemical Technician

Support Team : Manager, Auditor, Power House Supervisor, Maintenance Supervisor

Coordenador CICEMAIA

Coordenadora Meio AmbienteIS0-50001

RENATA

FacilitadorGUSTAVO

FacilitadorOSIEL

TNC ETECH PRODUÇÃO

ENT BARBAN SILVA

CAL LINCON RODRIGUES

BBS SIA TARDIO

DIVISÃO - A


CON DAMIÃO DARIO

VUL CASTANHARO MEDEIROS

FIN CASTANHARO MIGUEL

DIVISÃO - B1


COM OSTI ANDRÉ

VUL CELSO PIGATTO

OTR MEFFE DIAS

PREP MEFFE OSTI

DIVISÃO - B2 / P3

TNC ETECH

FACILIDADES

FAC NADAI

TNC ETECH

UTILIDADES

UTIL ALVES

TNC

ENT

CAL

BB

RICARDO

ALYSSON

GEISUN

REPRESENTANTES CICE

DIVISÃO - A

TNC

CONS ANA

REPRESENTANTES CICE

DIVISÃO - B1

VULC PEDRO

TNC

VULC

CONS

PREP

P3

MICHEL

ZANAGA

MACIEL

REPRESENTANTES CICE

DIVISÃO - B2 / P3

NILSON

TNC

STOCO

REPRESENTANTES CICE

FACILIDADES

FACCARLOS

TNC

SUB OSIEL / FIRMINO

GERALDO

EDSON

REPRESENTANTES CICE

UTILIDADES

CF

PPP

REPRESEN.

COORD.

PRODUÇÃO

22 Energy Team

Champions

(all part-time)

Energy Performance Metrics (EPM) Boards

- DMAIC Methodology


• Plants conduct a monthly meeting with Production Mgr, Business Center (BC) Managers, BC Energy Champions and Energy Coordinator

• The plant energy performance is displayed on the left-hand charts

• BC updates the action plan list monthly

• BC will choose the appropriate energy chart to display next to the action plan to track performance

• Icons used on the plant layout will show a visual of the concentration of energy initiatives in each BC

Energy Performance Metric (EPM) Topeka

Trend Chart BC $$

Trend

Trend

Action Plan

Action Plan

Action Plan

Action Plan

Action Plan

BC energy

Chart

BC energy

Chart

BC energy

Chart

BC energy

Chart

BC energy

Chart

Energy/GHG Performance Metrics (EPM)

- Boards standardized in all regions


2012 NAT Top 10 Energy Initiatives Dashboard

Scoring Month: Jan-2012

Metric # 1 2 3 4 5 6 7 8 9 10

Date Updated

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Weight % 15% 15% 5% 10% 5% 10% 10% 10% 10% 10%

Consumer Compliance (%) 63.8%

02/01/12 g y g g g g y y g g 82.5%

01/01/12 r g g y g g y r g g 65.0%

01/01/12 r g g g g g g r g g 75.0%

01/01/12 g y g g g g g r g g 82.5%

02/04/12 g r y y r r r r r r 22.5%

02/04/12 r g g g g y y r y y 55.0%

% Green 50% 50% 83% 67% 83% 83% 33% 0% 67% 83%

% Yellow 0% 33% 17% 33% 0% 0% 50% 17% 0% 0%

% Red 50% 17% 0% 0% 17% 17% 17% 83% 33% 17%

Commercial Compliance (%) 67.5%

01/01/12 g y g g g g g y g g 87.5%

02/01/12 r g g g g g y r r g 60.0%

02/01/12 g g g Y g y r r r g 60.0%

02/01/12 r g y y g y y y g g 62.5%

% Green 50% 75% 75% 50% 100% 50% 25% 0% 50% 100% NAT

% Yellow 0% 25% 25% 50% 0% 50% 50% 50% 0% 0% 65.6%% Red 50% 0% 0% 0% 0% 0% 25% 50% 50% 0%

Green Achieved (Full Credit) Yellow Partially Achieved (Half Credit) Red Not Achieved (No Credit)Score Keys

Indicators Energy Team Major Energy Initiatives

Energy Initiatives Scorecard:

Monthly Dashboard


Energy Monitoring System

- FT EnergyMetrix Central Server

Goodyear - A Sustainability Journey

Cannot manage what cannot be measured

17

Energy Monitoring System

RS EnergyMetrix Centralization Project

Phase I: Pilot Plant – connecting 100 meters to the new Akron server

Phase II: Connecting the remaining NA plants to the server

Plants will receive training on connecting existing and new meters/systems

Phase III: Expand the meters infrastructure in the plant

Level I: Plants main utility meters

Level II: Business Center utility meters

Level III: Critical equipment utility meters


NA, LA, AP and EMEA Energy Management System

- Energy Monitoring Central Servers

Goodyear - A Sustainability Journey

RSEnergyMetrix

10k Mgr meters

10k OPC

Real Time

Charts Plus

Reports Plus

Windows Server OS

SQLServer

Temporary License 9

months

Customer Provided

Computer

Existing

RSBizware

To be eliminated

NEW DATA

CONCENTRATOR

TO CONTROL

NETWORK UP TO

100 METERS

Akron

Danville

Asia Pacific Server– India, Indonesia,

Thailand, India,

China, Japan

Data Concentrator

Avg. cost $10,000

LA

NA & LA Server

Asia Pacific Server

EMEA Server

NA

EMEA Server– Germany, Poland,

France, UK, LUX,

Slovenia, Turkey, South

Africa

19

REPortal – New EHS&S data management system

• The EHS&S system REPortal system, a Goodyear in-house developed system

• Goodyear needs to improve the way data is collected and reported by plants

• Our goals:

– Every piece of EHS&S data is entered only once

– EHS&S data co-located with Production, Cost and Supply Chain data.

– Automated reporting of EHS&S data

• The project was done in multiple phases

– Phase I was called PDERT is a temporary solution to be replaced by a permanent

solution

– Phase II is the final phase that will combine the multiple system into one

– Data from the database will be loaded into the EDW on a monthly basis

– Automated reports will be distributed for the monthly data loaded into EDW


Summary: Old EHS&S System


RPM

(ergonomics)

MyRisk

(fire safety)

ORdB

(health & safety)

Lotus Notes

(environmental metrics)

Lotus Notes

(solvents)

Global Operations Planning

Deck Template

(AOP)

MAPS

(sustainability metrics)

Monthly/Quarterly PowerPoint Reports and Global AOP Deck

Local EHS&S Staff

Summary: New REPortal

22Goodyear - A Sustainability Journey

Summary: New REPortal


RPM

(ergonomics)

ORdB

(health & safety)

Monthly/Quarterly Reports

Local EHS&S Staff

Historical data from all

systems 2007*some data does not go back that far

* AOP system design not finalized

REPortal web

portalMyRisk

(fire safety)

MAPS, Lotus Notes Env. Metrics and

Global Solvents Database not part of

new system

Questions & Discussion


goodyear global energy- ghg systemsupplierspartnership.org/members_only/2014-09 abdrabou -...

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