results and impact in the - ncpc.co.zancpc.co.za/files/guides/iee in the automotive sector.pdf ·...
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energyEnergy Swiss Confederation
Federal Department of Economic Affairs FDEA
State Secretariat for Economic Affairs SECO
Results and impact in the Automotive
Sector
www.iee-sa.co.za
Industrial Energy Efficiency Project in South Africa
Overview
• IntroductiontotheIEEProject.............................2
• TheSouthAfricanautomotivesector:
Asnapshot.............................................................4
• TheIEEProject’sautomotive
sectorjourney........................................................ 8
Equipping industry for energy efficiency (IEE training)........................................12
Casestudy:Toyota–leadingtheway..................13
Energy efficiency boost with international standard certification (ISO 50001)..............................................................16
Casestudies: ISO 50001 certified companies:
• Tenneco...............................................................18
• JohnsonMattheySouthAfrica.......................... 20
Other sector energy efficiency case studies:
• FeltexAutomotive...............................................22
• ToyotaBoshokuSA..............................................28
Energy efficiency and small, medium and micro enterprises..........................................30
CasestudiesinSMEs:
• Techniplate..........................................................32
• PrecisionPress......................................................34
Contents
1
2
Toachievethis,theprojectemploysaholisticapproachbasedonanumberofkeyelements,orcomponents:
• Encouragingthecreationofanenabling policy environment;
• Supportingtheadoptionandpromotionofenergy management standards(ISO50001);
• Building local capacitytoimplementEnMSandESOinindustrialenterprises,throughspecialisedtrainingcoursesandextensivein-plantimplementationsupport;and
• Demonstrating the potential and impactofIEEonthebottomlineandsustainabilityofabusinessthroughcasestudies,demonstrationplantsandawareness-raising.
ServicestoindustryTheIEEProjectcurrentlysupportsSouthAfricanindustrythroughasubsidisedservicemodel.ParticipationintheProjectisatnocosttocompanies.
EnergyManagementSystem(EnMS)implementationTheIEEProjectassistscompaniesindevelopingandimplementinganEnMSinlinewiththeSANS/ISO50001EnergyManagementStandard,andsupportcompanies’effortstoachieveISO50001certification.
Implementationtakesplaceoveraperiodof9to12monthsandcaneitherbefacilitatedinternallybythecompanywiththesupportoftheIEEProject,orbyanIEEProjectEnMSexpert,withthecompanyagreeingtoserveasdemonstrationprojecttoshowcasethebenefitsofEnMS.
EnergySystemsOptimisation(ESO)implementationTheIEEProjectequipscompaniestosystematicallytargetselectedsystemswithintheirprocessingfacilitiesandinterrogatetheirperformanceandeffectiveness.Currentlysupportisavailablefortheoptimisationoffiveenergyintensivesystems,namelysteam,compressedair,fans,pumpsandelectricmotors.
OverviewTheIEEProjectwaslaunchedin2010andaimstocontributetothesustainable
transformationofindustrialenergyusagepracticesinSouthAfrica,therebyreducing
carbon-dioxideemissionsandpressureonenergyresources,whilstdemonstratingthe
impactofenergyefficiencypracticesintermsofmonetaryandenvironmentalbenefits.
Since2011,theIndustrialEnergyEfficiencyProject(IEEProject)inSouthAfricahasassistedindustrytosave over R 344 million inenergysavingsthroughtheimplementationofEnergy Management Systems (EnMS)andEnergy Systems Optimisation (ESO)in54 industryplants.
3
ExpertskillsdevelopmenttomaximiseenergyefficiencyToensurethedevelopmentofskillsneededtosustainenergyefficiencyinindustry,trainingcourseshavebeendevelopedtotrainprofessionalsinEnMSandESOinavarietyofindustrialsystems.
Trainingispresentedattwolevels:atechnicaladvancedlevelofferedinatwo-dayworkshopformat,andexpertleveltraining,whichiscompletedoveraperiodofmonthsandincludestheoreticalandin-planttraining,andanactualworkplaceimplementationcomponent.MoredetailsontheIEEprojecttrainingisprovidedonpage12.
PrivatesectorparticipationopportunitiesInadditiontotheservicesalreadymentioned,industrialenterprisescanparticipateandbenefitfromtheIEEProjectbybecominga:
HOSt OR canDIDatE plantByallowingexpertleveltrainingattheirplants,companiesareenabledtoidentifyenergysavingopportunities.InthecaseofESO,participatingcompaniesreceiveasystemsassessmentreport,compiledbyUNIDO/NCPC-SAexpertsatnocharge.Theyalsoqualifyfortheenrolmentoftwodelegatesintheadvancedtrainingprogrammeandoneintheexpert-levelprogrammeatnocharge.
DEMOnStRatIOn plantCompaniesthatchoosetoimplementsomeoralloftherecommendationsfromtheassessmentreporthavetheopportunitytovolunteerasademonstrationplant.TheIEEProjectwillpartnerwiththecompanytodevelopacasestudyontheimplementationprocessandtheenergysavingsresultingfromit.Thecasestudywillbeusedonnationalandinternationalcommunicationplatforms,increasingthevisibilityofthecompany.
component Optimisation vs. Systems OptimisationThetraditionalcomponentsapproach–analysingtheperformanceofvariouspartsor
componentsofasystemandaddressinghowtomaketheseworkbetter–typicallyresults
inanenergysavingofbetween2%and5%,whereasevidenceindicatesthatasystems
optimisationapproach–lookingathowanentiregroupofpartsofcomponentsfunctions
togetherandhowchangingonewillimpactonothersandthesystemasawhole–
achievessavingsof10%-50%.
Did you know?
4
TrendsGlobaltrendsshowthattheautomotiveindustryhasimproved.Annualproductionhasescalatedandprofitsforglobaloriginalequipmentmanufacturers(OEMs)areexpectedtoincrease(The South African Automotive Industry: An overview, B&M Analysts, August 2014).Whilesignsofrecoveryfromtheeconomiccrisisareencouraging,somechallengesstillexist.Theseincluderegulatorypressuresaroundemissionsandsafety,andincreasingcompetitionfromemergingmarkets.
SouthAfricantrendsshowthatannualsaleshaveescalatedsince2012.Importsanddomestically
producedvehiclescontinuedtorecoverin2013butsalesarefarbelowthosereportedfor2006.
Whileexportsremainthefocuswithproductionoutputincreasingfrom28%in2005toanestimatedvalueof54%in2013,newvehicleexportsinNovember2013showedadeclineof4.8%incomparisontothesameperiodin2012,duetoindustrystrikes.
Ingeneral,theSouthAfricanautomotiveindustryshowedmodestgrowthin2013andtheprojectedincreaseinexportsalesfor2014bodeswellforapositivecontributiontothecountry’seconomy.
a snapshotDevelopingcountries,increasinglyintegratedintotheglobalautomotivevalue
chainofglobalrole-players,notonlyhavetocopeandincorporatethedirectimpact
ofthemajorglobaltrendsontheiroperations,butalsohavetocompetewitheach
otherforsourcingandoutsourcingopportunities.
“Itiswithinthisfastchangingenvironmentthatmanydevelopingcountries,suchas
SouthAfrica,areseekingtocreateforthemselvesaroleasproducerofvehiclesand
automotivecomponents.TheSouthAfricaautomotiveindustrypossessesunique
qualitiesandanaturalabilitytoaddvaluetoglobalstrategiesofparentcompanies
andmultinationals.SouthAfrica’sattractivenessasaninvestmentdestinationofchoice
andproductionbaseforproductstobeexportedtoglobalmarketsisincreasing.
automotive Export Manual 2013
the South african automotive sector:
5
AutomotivesectorsignificantThepotentialofthesectortocontributepositivelytotheSouthAfricaneconomyhasbeenrecognisedbygovernmentinvariousforaandhasledtoanumberofinitiativessettostrengthenthesector.
ThefirstIndustrialPolicyActionPlan(IPAP)launchedin2007/2008,identifiedtheautomotiveproductionsectorasacriticalsegmentoftheeconomy.Contributingsome7%toSouthAfrica’sGDPandbeingresponsiblefornearly12%ofthecountry’smanufacturingexports,thesectoralsoholdsgreatpotentialforjobcreation.
AccordingtotheAutomotiveExportManual2013(producedbytheAutomotiveIndustryExportCouncil(AIEC)),some65000peopleareemployedinthecomponentmanufacturingindustry,28000aredirectlyemployedinautomotivemanufacturingand200000peopleinretailandaftermarketactivities.
Focusinginitialeffortsontheimplementationofsectoralplansforautomotivesandcomponents,IPAPundertookthedesignandimplementationofanindustrialupgradingprogramme,revisedindustrialfinancingmechanisms,reducedinputcoststhroughtheimplementationofacompetitionpolicy,andreviewedimportdutiesonintermediategoods.TheautomotiveindustryremainedakeyfocussectorinIPAP2(2010/11–2012/13),whichaddressedthescalingupofsector-specificinterventions.
EvenpriortoIPAPandsimilarinitiatives,thepotentialoftheindustryandtheneedforittoremaincompetitiveinordertosurvivegloballywererecognisedinapartnershipbetweenUNIDOandtheAutomotiveIndustryDevelopmentCentre(AIDC)intheearly2000s.
KnownastheTirisanoClusterProgramme,theUNIDO-AIDCpartnershipaimedtoraiseoperatingefficiencyatplantlevel.Focusareasincludedreducingwasteanddowntime,improvingworkersafetyandstrengtheningteamworkamongsupervisorsandshopfloorworkers.
OneoftheadditionalmodulesaddedtotheTirisanoClusterprogrammeconcernedcleanerproduction.CleanerproductiontrainingisprovidedbytheNationalCleanerProductionCentretohelpcompaniesidentifywaystosavecostsinenergyandwater,specifically.
TheSouthAfricangovernmenthasfurthercorroboratedtheimportanceofthesectorthroughanumberofpolicydocumentsandprogrammes,includingtheMotorIndustryDevelopmentProgramme.ThiswassucceededbytheAutomotiveProductionandDevelopmentProgrammein2013tofurtherstimulatelocalproductionto1.2millionvehiclesayearby2020aswellasincreasinglocalcontent.
IncreasingcompetitivenessGauteng,theEasternCapeandKwaZulu-Natalarehometothebulkofthecountry’svehiclemanufacturingactivitieswithactivitiestakingoffintheWesternCapeandNorthWestprovincesaswell.Thenumberofexportdestinationsforvehiclesandcomponentsisincreasing.AccordingtotheAIEC,thenumberofexportdestinationsforvaluesinexcessofR1millionhasincreasedfrom62in1995to130in2011andto152in2012.
Thegreeneconomyhasbeenasubjectofdiscussionforsomeyearsandalsofeaturedstronglyatthe2011SouthAfricanAutomotiveWeek,heldinEastLondon.Hereitwassaidthat“SouthAfricanautomotivemanufacturershavetoadjusttothegreeneconomyiftheyaretosurvive.”
WithroleplayerssuchasUNIDOandtheNCPC,throughtheIndustrialEnergyEfficiencyProject,andthecommitmentfromvehicleandcomponentmanufacturers,someinroads–withsignificantfinancialandothersavings–havealreadybeenmadeinsupportofagreeneconomy.
6
GDPcontribution
SouthAfrica’srankingin
globalvehicleproduction
CapitalexpenditurebyOEMsfrom1995to2012
RegisteredvehiclesatendofDecember2012
Registeredvehiclesin2012comprisedpassengercars
7% R48,6 billion
10,61 million
6,11 million
25th
(source: automotive Export Manual 2013)in numbers
the automotive industry
South African industry trends – vehicle production for domestic and export markets
Source: NAAMSA, 2013
Domesticallyproducedvehiclesfortheexportmarket
Exportsas%oftotaldomesticproduction
Domesticallyproducedvehiclesforthelocalmarket
700000
600000
500000
400000
300000
200000
100000
0
70%
60%
50%
40%
30%
20%
10%
0%
Uni
ts
perc
ent
00 01 02 03 04 05 06 07 08 09 10 11 12 13* 14* 15*
Year
7
Vehiclebuilders
Vehiclecomponentmanufacturers
newcardealerships
Specialistrepairers
Garagesandfuelstations(withmostalsoofferingservice
workshops)
167
292
1 374
1 898
4 600Partsdealers
2 907
South African industry trends – South African OEM industry profile for 2013
Cost competitiveness of South African component producers
Automotive component producers: Input costs
Sa thailand UK
2.40%
2.36%
2.16%
12.45%
3.27%
1.36%
1.83%
6.02%
2.88%
5.89%
3.70%
10.68%
Rental
Electricity
Water
Employment
25%
20%
15%
10%
5%
0%
% o
f Sa
les
19.37%
12.49%
23.16%
1,042.87
12%
929.14
0%
1,014.45
9%
50%
45%
40%
35%
30%
25%
20%
15%
10%
5%
0%
R1,060
R1,040
R1,020
R1,000
R980
R960
R940
R920
R900
R880
R860Sa thailand UK
OutputPrice
Disadvantage
R1,014
9%R929
0%
R1,043
12%
Va
lue
perc
ent
ag
e
Circle size represents vehicle
sales volume (units)
100%
80%
60%
40%
20%
0%
-20%
Exp
ort
s (%
)
20,000 60,000 80,000 100,000 120,000 140,000 160,000 180,000
OEMproduction Vol
Export %Sales Vol
tSa151,23152.97%122,801
VWSa106,61048.85%110,779
BMW66,08782.01%27,671
FMcSa57,03260.49%64,350
nSa46,23531.64%59,557GMSa
39,4063.79%58,724
MBSa47,18976.77%28,453
production Volume (Units)
40,000
8
TheIndustrialEnergyEfficiency(IEE)Project’sjourneyintheautomotivesectorstarted
inlate2010whenNationalCleanerProductionCentrestaffandUNIDOengagedwith
automotivecompaniestoparticipateintheheavilysubsidisedIEEProject.
automotive journey the IEE project’s
Energy savings reported by participating companies in the automotive sector (as at March 2014)
company kWh Savings Rand Savings
tonnes cO2
*
Energy Systems
MercedesBenz 2800000 R1540000 2682 Compressedairsystem
ToyotaSA* 33300000 R18315000 31901 103projects
PrecisionPress 334000 R183700 320 Compressedairandidlemachines
TennecoEmissionControl
600000 R330000 575 Lighting
TennecoRideControl 2360000 R1298000 2261 Oven,knives,inductiongeyser,VSD
WillardBatteries 5600000 R3080000 5365 Curingtime,wetscrubbers,charges
Techniplate 840000 R462000 805 Timeswitchesandtempsensorstoplatingtanks
BMW 17700000 R9735000 16957 Paintshopovens,driers
Feltex 2600000 R1430000 2491 Coolingcomp,lights,idlemachines
JohnsonMatthey 9400000 R5170000 9005 Compressors,chillers,idlemachines,ovens
total 75 534 000 R 41 543 700 72 362
*Toyota SA has reported on updated savings (June 2014) in the article on page 13
AlfHartzenburg,nationalIEEProjectmanager,remembers,“Itwashardinthosedaysbecausecompaniesweresceptical,didnotknowanythingabouttheprojectandwerehard-pressedtodeliverontheirowninitiatives.”
ThefirstawarenesstrainingsessionsinDurban,CapeTownandPretoriatargetedseniormanagementasitwasclearfromthestartthatforenergyefficiencytobetakenseriouslyandaccruethepotentialbenefits,buy-infrommanagementwascritical.
ItstartsatthetopHartzenburgexplains,“Managementbuy-ininactioniscritical.Thistranslates,forexample,inensuringtheenergymanager’sjobdescriptionissufficientlytargetedtoimplementandmanageenergyplans.Thismustalsobeakeyperformanceindicator(KPI)thatdevotesatleast20hoursamonthtotheEnMS.EnergyKPIsareimportantforallmanagers.
“Managerscanalsodemonstratetheircommitmentbywalkingthetalkandbyengagingstaff.Switchingofflightsaftermeetingsisoneofthemostobviousthingstodoandwhileitmightnotresultinabigcostsaving,itdoeshaveabigimpactoneffectingbehaviouralchange.”
9
Hartzenburgadds,“TheEnMSallowsonetosystematicallychipawayatthetargets,monitorandkeeptrackofnewopportunitiesforenergysavingprojectsandperformanceofexistingprojects.”
Takingthelead“Toyotaembarkedonitsenergyefficiencyjourneyayearearlierandithadtonavigatemanydifficultdiscussionstoconvinceitsglobalparentcompanyaboutthemeritsofreviewingcurrentenergymanagementplans,”Hartzenburgexplains(readarticleonpage13).
“ArdenWessels,whowithhiscolleagueSheldonBodeattendedthefirsttrainingsessionsin2010,wasappointedasenergymanageratToyotain2009.Hestartedbymonitoringandloggingtheenergyelectricityconsumptionperunit,perregionandperassembly.Hedevelopedadatabasewhichhelpedtoidentifyopportunitiesforimprovementandthroughaproject-basedapproachstartedtotackleeachissue.
“Hisbattle–andwe’veseenthistoberelevanttoothercompaniesaswell–wasnotonlyontheshopfloorwithoperationsandplantmanagementbutalsowithotherdepartmentssuchasprocurement
andshopfront.Slowlytheireffortsstartedtoshowsavings.Ashiscredibilitygrew,hewasallowedtoestablishanenergyteamoffouryounggraduateengineerstodriveenergyconsumptiondown.
“ThiswasaburningplatforminToyotabecausethatspecificplantwasthemostinefficientplantintheworldfromanenergyperspective.TheToyotastoryisaverypositivesuccessstorybecausebycontinuingwiththeirinitialprojectsaswellasdevelopingandimplementinganEnMSthroughtheIEEProject,
potential Savings identified through energy audits in SMEs
Sector Rands/annum % (R/a) kWh/annum % kWh/a
Agro-processing 50394755 0.45 48106764 0.44
automotive 13 928 814 0.12 11 052 155 0.10
Chemicals,Plastics&Pharmaceuticals 13727194 0.12 14906851 0.14
MetalAllied&Engineering 21887111 0.20 27276480 0.25
Manufacturing 3877385 0.03 875581 0.01
Pulp&Paper 292799 0.00 139181 0.00
Clothing&Textile 3135224 0.03 1626031 0.01
Other 4354973 0.04 4847573 0.04
tOtal 111 598 255 108 830 617
the IEE project offers three main services to industry:• Energyaudits(mostlyforSMEs)toidentify
andadviseonpotentialsavingsinaplant
• EnMSandESOinterventionsupport–thisalsoincludessupportineffortstoattainSANS/ISO50001certification.
• TraininginEnMSandESOtocapacitateindustrytoimplementenergyefficiencyinthelongterms.
Inalloftheseareas,theautomotivesectorhasbeenanenthusiasticparticipant,makingtheresultsandimpactagoodnewsstory.
10
Ardenandhisteamtooktheplantfrombeingtheworsttobeingoneofthethreetopenergyefficientplantsintheworld!”
“Toyotashowedwhatcanbeachievedanditwasn’tverylongthatthenewsspreadandthegrapevineextendedintotheEasternCape.”
HartzenburgsaysthatWesselssoonhadhishandsfullwithenquiriesfromEasternCapecompaniesthatwantedtoknowmore.Asadirectresult,Tenneco(seepages17-19)cameonboard.
DialogueimprovedwithintheindustryandthroughtheIEEProject’sfacilitation,companiesengagedeachotherthatwouldnotnormallydoso.Theydiscoveredthatenergywasnotaconfidentialissuebutauniversallanguage.”
Tenneco’sjourneyagainillustratestheimportanceofmanagementbuy-in.“JustinBotha,TennecoMD,tookastronglead.Infact,hewantedtoimplementthethennon-existingEnMSinsixmonths–somethingthathasneverbeendonebefore!InthatsamemeetingTenneco’sexistingenvironmentalpolicywasamendedtoincludeenergy,signedoffthereandthenandworkstartedimmediately,”relatesHartzenburg,applaudingBotha’s‘can-do’attitude.
TennecowasalsothefirstcompanyontheIEEProjecttocallforsupporttotrainitsprocurementpeopleandmaintenanceengineers.FromthesavingsaccruedthroughitsEnMS,Tennecowasabletoprocureastate-of-the-artcompressor.
automotive journey the IEE project’s
(continued)
11
GrowinginterestVolkswagenenquiredabouttheIEEProjectearlyon.HartzenburgvisitedtheUitenhageplanttwiceandwasthenaskedtodoagapanalysisbetweenVolkswagen’sexisting
energyefficiencyprogrammeandtheIEEProject.DeficiencieswerepointedoutandinNovember2013about35representativesinmainlytheengineeringandenvironmentalsustainabilityareasofVolkswagenattendedatrainingsession.Anothertwoworkshopsfollowedandthis,togetherwithincreasedpressurefromGermanytobeISOcertifiedbyNovember2014,addedimpetustotheestablishmentandimplementationoftheEnMS.Hartzenburg’steamisnowhelpingVolkswagenprepareforcertification.
Daimler Benzhasalsoshownitscommitmentbysending
ateamoffourtoattendthetrainingin2012.ItsignedupasahostcompanyfortheIEEProject’scompressedairsystemtraining.“Wearehelpingthecompanytoprepareforcertification.TheurgencyissuchthatittwinnedwithaplantinGermanythathasalreadyreceiveditsISO50001certificationtospeeduptheprocess,”saysHartzenburg.
Thecompanyhasachievedasavingof2800000kWhandR1540000throughchangestoitscompressedairsystemalone.
Willard Batteries’energysavinginitiativesaredoingwellanditshighlydedicatedteam
is,alignedwiththelargerglobalgroup,pursuingatargettoreduceenergyby5%perannum.Internalcommunicationandawarenessraisingofitseffortshaveaddedtoitssuccessandincludeactivitiessuchasdailyenergyusagecostsfixedoneachofficedooraswellasremindersonbasicwaysto
cutdownelectricityusage.Energyawarenesstrainingisongoing.
CompletedactionsincludealteringthechargingprofilesofbatteriestoreduceAhinputintobatteries;automaticswitchoffofchillers,conveyorsandextractorsduringproductionstoppages;airleaksurveyandrepair;alightingupgradewhichsawalllightsonthepremisesreplacedwithlowenergylighting–thisinterventioneffectedarebatefromEskomanda393078kWhsavingperannum.
Ablutiongeyserelementswerereplacedbyheatpumps,forwhichthecompanyreceivedanEskomrebateof50%andasavingof59545kWhperannum.Changingtoagasstoveinthecanteeneffectedasavingof44912kWhperannum.
Curingtimeforplatemakingwasreducedwithsavingsamountingto1306800kWhandapaybackof2.5years.Bagfilterswerereplacedwithwetscrubber,effecting817344kWhsavingswithatwo-yearpaybackperiod;andsavingsbyreplacing10AchargersintheChargeRoomamountedto693505kWhwithapaybackof3.9years.
YunusMoolafromWillardBatteries’parentcompany,PowertechBatteries,says,“Ourworkisnotdoneyetandtheteamiscommittedtoreachingitsenergysavingtargets.Internalauditsareplannedforearly2015withISO50001certificationfollowingin2016.”
TheIEEProjectwillcontinuetoenablecompaniestoreapenergyefficiencyrewards.Energyefficiencyhasbeenproventosaveindustrialfirmsmoney,increasethereliabilityofoperations,improvesecurityofsupplyandofferattractivefinancialandeconomicreturns,whilepromotingjobcreationandreducingcarbondioxideemissions.
12
tRaInInG IS pRESEntED at tWO lEVElS:
• Atechnicaluser(advanced)levelofferedinatwo-dayworkshopformat,and
• Expertleveltraining,whichiscompletedoveraperiodofmonthsandincludestheoreticalandin-planttraining,andanactualworkplaceimplementationcomponent.
Selected expert level graduates recently qualified as trainers to take over from international UNIDO-appointed facilitators. During the last quarter of 2013, the first South African professionals also qualified to lead audit teams to certify companies as ISO 50001 compliant.
tRaInInG pROGRaMMES aRE pRESEntED In tHE FOllOWInG EnERGY SYStEMS:
• FanSystemsOptimisation(ESOFans)
• MotorSystemsOptimisation(ESOMotors)
• CompressedAirSystemsOptimisation(ESOCompAir)
• PumpSystemsOptimisation(ESOPumps)
• SteamSystemsOptimisation(ESOSteam)
Equipping industry for energy efficiency
Todate,theIEEProject
hastrained over 2,200individualsatadvancedlevelandaround
80 IEE experts
IEE Project (UNIDO) Training
Theavailabilityofspecialisedskillsiscriticaltothesustainabilityofenergyefficiency
initiativesinindustry.CourseshavethereforebeendevelopedbytheIEEProject,
undertheleadershipofUNIDO,totrainprofessionalsinEnMSandESOinavarietyof
industrialsystemsinuseinmanufacturing,miningandotherindustries.
Moredetailsofcoursecontent,thetrainingeventdatesandonlineregistrationareavailableon www.iee-sa.co.za
13
Inanationwheretheelectricitysupplyreservemarginislowandenergycostsrapidlyincreasing,itisnotonlygoodcorporatecitizenrytoreduceenergyconsumptionbutitalsomakesgoodbusiness-sense.
InItIal StEpSToyotaSouthAfricaunderstandsthisandin2008,ToyotaSA(Durban)identifiedenergysavingasoneofitspriorityfocusareas.Arepresentativefromeachofthe14ToyotaSAplantswascalledtobepartofaworkinggrouptaskedwithidentifyingareasforpossibleenergyconsumptionreduction.
Toyota’scompanypolicyistoconsiderallenergyinitiativesthatshowapaybackperiodoflessthantwoyears.Foraddedmomentumtoexistingprojects,ToyotaSAsignedupasahostplantfortheIndustrialEnergyEfficiency(IEE)ProjectinAugust2010.
(A host plant ‘hosts’ IEE Project expert level training at its plant, which automatically allows it two delegates at the expert training.)
AllrelevantToyotapersonnelenrolledfortheuser-level(2day)EnergyManagementSystems(EnMS)andEnergySystemsOptimisation(ESO)trainingprogrammeofferedbytheIEEProject,withtwocandidatessuccessfullycompletingthefirstexpert-levelEnMStrainingcourse(2010/11)andonegraduatingfromthePumpSystemsexpert-levelcoursein2012.
AnEnMSwasintroduced,alongwithanumberofESOandenergyefficiencyprojectsacrossvariousoperationalareas.InlinewiththeISO50001approach,ToyotaSAsetupaPlan-Do-Check-Act(seepage17)processtoensureeffectiveimplementationoftheEnMS,includingregularandaccuratemonitoring.Aspartoftheimplementation
Leading the way
DEDIcatED RESOURcESInApril2012thecompanysetupadedicatedEnergyManagementDepartmentconsistingofaseniormanagerandfourengineers,eachdedicatedtoaparticularclusterofplantswithinToyotaDurban.Thesecomprised:
• Paintandutilitiesplants;
• Vehicleandcomponentassemblyplants,andassemblypartswarehouses;
• Weldingplants;and
• Non-productionareas(administrativeareas).
ArdenWessels,ToyotaSeniorManager:EnvironmentalEngineering&Compliance,attributesthesuccessoftheEnMSandESOinitiativesatToyotaSAto“thesupportofbothtopmanagementandthemanagersoftheplantsconcerned”.
caSE StUDY
AcasestudyforthisfirstyearoftheEnMSisavailableontheIEEprojectwebsite,
www.iee-sa.co.za
Early successes – toyota energy improvements 2010 – 2011
TotalNo.ofProjects 55
GrossMonetarySavings R4,847,000
EnergySavings GWh8.15
TotalInvestment R3,350,000
OverallPaybackPeriod(inyears)
1.09
GHGEmissionsReduction tonCO27,8043
ofanEnMS,energyauditswereconductedatall14ofitsplantstoidentifysignificantenergyusers.
Atotalof55projectswereimplemented,realisingsavingsof8.15GWh(R4.8million)inthefirstyear.
caSE StUDY
14
Hesaysthat,“Plantpersonnelinalltargetedareashavetobeengagedthroughouttheplanningandimplementationstagestoensurethenecessarysupportandtoovercometheperceptionthatenergyreductionstepswouldimpactnegativelyonsafety,qualityorproductioncycletimes.”
plan, DO, cHEck anD actToyotaisthelargestvehiclemanufacturerinSouthAfricaandafull
affiliateoftheToyotaMotorCorporation.“Globally,thecompanyisdrivenbyaggressiveenvironmentaltargetstoreduceenergyandwaterusage,vehicleemissionsandwaste,”Wesselssays.“Wearefullycommittedtocostreductioninitiativesthroughmoreefficientuseofenergyandwaterandconstantlycreateawarenesswithemployeesandsuppliersonthebenefitsofenergymanagement.Afterfouryearsofconsistentreturnsonenergymanagementefforts,wearepreparingforISO50001certificationtodrivesustainableimprovements.”
InfollowingtheISO-alignedEnMSPlan-Do-Check-Actprocess,Wesselsemphasisesthatseniormanagementcontinuestoplayaleadingrole.Infact,eachgeneralmanagerofeachplanthasenergyandwaterasakeyperformanceindicatorandsettargetshavetobemet.
Intheplanningphase,ToyotaestablisheditsEnergyPolicyandidentifiedandprioritisedsignificantenergyusers.Anenergybaselinewasestablished,energyperformanceindicatorsidentifiedandmeasuredinkgCO2pervehicle.Finally,energyobjectivesandactionplanswereputinplacetoreachtargets.
Inthefollowingphase,actionplanswereimplementedandtrainingandawarenessprogrammescarriedoutandcommunicatedacrossthecompany.Energyimprovementwasalsoconsideredinneworrenovatedfacilities.
Energyismonitored,measuredandanalysedweeklyandmonthly,andinthefinalphase(Act),topmanagementreviewstheEnMSandenergyperformanceonaquarterlybasis.
pROGRESS“Wehavecompleted103projectssinceApril2010andhaveidentified11moreforthisfinancialyear,endingMarch2015.Fiftyofthe103projectsrequirednoadditionalfinancialinvestment.”Wesselsadds.
Projectsvariedandhadbothfinancialandenergysavings.Threeprojectsarehighlightedbelow.
Oneofthe103projects,gassupplyconversion,hadmanyadditionalbenefits.Wesselsrecounts,“Weconvertedfromliquidpetroleumgastocompressednaturalgas.Apartfromfinancialsavings,wearealsoreapingsafetybenefits.Thetankcanbefilledwhilethedriverisonthevehicle,fillingtimeisquicker,andCO2emissionsarelower.”
Buttherealsuccessstory,Wesselssays,isthatToyotaSAhasshownayear-on-yeardecreaseinenergyconsumptionwhilealsoachievingayear-on-yearincreaseinbuildingvehicles.
Arden Wessels (left) receives the South African Energy Efficiency (SAEE) energy company of the year award in November 2013 at the annual SAAEC in Gauteng. SAEE bestowed this award in recognition of Toyota SA’s “ambitious environmental commitments and the aggressive approach taken to reduce energy usage, vehicle emissions and waste.”
(continued)Leading the way
15
Note: This kaizen (a term originally from Japan referring to ‘good change’ or continuous improvement) won a Toyota Global ECO award in 2013
project: Pumpoptimisation
process: CoolingWater
Objective: 3to2pumpsandmaintain 487m³/hflowrate
completed: 2010
project: CompressorOptimisation
process: Compressors
Objective: Setcompressorstorunonlywhen required–reacttodemand
completed: Phase1–2010 Phase2–2011,Phase3–2012, Phase4–2013
project: Chiller8OperatingPattern
process: PaintPlantWaterChiller
Objective: ProgramsmallerChiller8 torunonweekendsonly
completed: 2013
The true test of energy efficiency: Increasing annual volume while decreasing annual electricity consumption
cost R 38000
Energy saving kWh/y 322500
cost saving R/y 167700
payback months 3
cost R 0
Energy saving kWh/y 2442000
cost saving R/y 1693690
payback months 0
cost R 32500
Energy saving kWh/y 563100
cost saving R/y 444850
ROI months 1
pROJEct HIGHlIGHtS
Volume Increasing annually
FY07 FY08 FY09 FY10 FY11 FY12 FY13 FY14plan
Electricity(kWh)Volume
Electricity consumption Decreasing annually
200000
150000
100000
50000
0
co
nsum
ptio
n (k
Wh)
Vo
lum
e (
Uni
ts)
200000000
150000000
100000000
50000000
0
16
ISO50001wasadoptedbytheSouthAfricanBureauofStandardsin2011asthenationalstandardforestablishing,implementing,maintainingandimprovinganenergymanagementsystem.TheIndustrialEnergyEfficiency(IEE)Projectissupportinganumberoflocalcompaniesinworkingtowardsjoiningtheapproximately1800companiesworldwidewhohaveattainedISO50001certificationataround3000sites,mostofwhichareinEurope.
TheIEEProject’sHemantGroverexplainsthesignificanceofbeingISO50001certified,“Inanutshell,ISOallowsanyorganisationtomanageenergyinasustainableway.Previously,companiesthatwantedtomanageenergydidsobyimplementingadhocinterventionswithlittlesustainedrewardsorimpact.TheNCPC-SAusesitforsustainabilityandcontinuity.”
AnycompanywantingtobeISOcertifiedmustbecompliantandmustpassarecertificationauditeverytwoorthreeyears.Thatimpliesthatrecordkeepingisveryimportantasrecordsshowwhatissustainable.
“Energyhasnowbeenelevatedtofeatureinthebusinesscultureinsteadofbeinganice-to-have,”Groveradds.“MorethanadecadeagoinSouthAfrica,energywascheap.Thatchangedwiththeenergycrisisandabigboominindustry.Consultants
international standard certification (ISO 50001)
Energy efficiency boost with
SanS / ISO 50001:• Enablesorganisationstoestablishsystems
andprocessesnecessaryto improve energy performance;
• Isapplicabletoallorganisations;and
• Does notprescribespecificperformancecriteriawithrespecttoenergy
ISO50001istheonlystandardthatimpactsdirectlyonthecompany’sbottomline,asitaimstoreduceoveralloperatingcostsbydrivingdownenergyspending.
ISO50001ensuresthatenergysavingsaresustainedovertime:toremaincertified,acompanymusthavesystemsinplacetoensurethattheenergyefficiencyissustainableinthelongterm.
startedtoadvocatewaystochangeenergyconsumptionbutwithoutapropermanagementsysteminplace,theseinitiativesaredifficulttosustain.Europethendevelopedanationalenergystandard,inwhichUNIDOplayedakeyrole,andthisledtotheestablishmentofISO50001.”
AccordingtotheInternationalOrganisationforStandardisation,ISO50001isbasedon
themanagementsystemmodelofcontinualimprovementalsousedforotherwell-
knownstandardssuchasISO9001orISO14001.“Thismakesiteasierfororganisations
tointegrateenergymanagementintotheiroveralleffortstoimprovequalityand
environmentalmanagement,”theorganisationsays.
17
GroveremphasisesthatthefirststepintheprocessforbecomingISOcertifiediscommitmenttoenergymanagementfromthetopleadershipoftheorganisation.Theorganisationidentifiesthescopeandtheboundaries(whatandwhere)oftheenergymanagementrequired,andsetsupateamtodrivetheprocess.Theteamconstitutestopmanagementrepresentativesaswellasrepresentativesfrombusinessunits.Theenergymanagertakesthelead.
“Collectively,theteamoverseesmanagementanddetailedplanning.Theyneedtoknowexactlyhowmuchenergyisbeingused(alsolookingback);what,ifanything,wasdonetoreduceconsumption;howsuccessfultheseinterventionswere;whatarethebigenergyusers;andthenbasedonthisinformation,objectives,targetsandactionplansarecompiled.Thisisfollowedbyimplementation,monitoringandevaluationandsupplyingleadershipwithfeedback.
Tenneco in Nelson Mandela Bay was in the news in May 2014 for becoming the first automotive supplier in South Africa to achieve an international certification for its energy management systems.
Based on the successes achieved in the Nelson Mandela Bay plant, the certification is now being rolled out to all production facilities worldwide (some 90).
The ISO 50001 certification was achieved for the implementation of the energy management systems at two of its plants – Tenneco Ride Performance, which manufactures original equipment and aftermarket shock absorbers, and Tenneco Clean Air, which manufactures catalytic converters and exhaust assemblies.
The ISO 50001-aligned Energy Management System process is based on the concept of plan, do, check, and act.
ManagementReview Policy
ManagementResponsibility
Managementparticipation Yes
Implementation&Operation
Day to day operations
Checking
Planning
caSE StUDY
18
Overall plant efficiency improvements
tEnnEcO RIDE pERFORMancE (ptY) ltD anD tEnnEcO clEan aIR (ptY) ltD
tHE ISSUE anD MaIn FInDInGSTennecoAutomotiveisaninternationalautomotivesupplierwithmorethan90productionfacilitiesworldwide.TwoofthesearelocatedclosetotheautomotivehubinNelsonMandelaBay.
Tenneco–RidePerformance(Pty)LtdproducesshockabsorbersandTenneco–CleanAir(Pty)Ltdproducescatalyticconvertersandexhaustassembliesforboththelocalandinternationalmarkets.Tennecohasacombinedtotalof780employeeswhoallcontributetotheenergyconsumption.Annualproductionofeachplantisaround2.2millionunitsperannum.
TennecoSouthAfricabecameawareoftheIEEprojectatatwo-dayEnergyManagementSystems(EnMS)trainingsession.Followingadecisiontojoin
thefullEnMSexpertcourse,TennecowasselectedasthehostcompanytoshowcasetheimplementationofISO50001withsupportfromtheIEEproject.
EnERGY cOnSERVatIOn OppORtUnItIES IDEntIFIEDTennecohassetitssightsonISO50001fromthedayitwasreleased.ProgresstowardsISO50001wasagreatlearningexperiencesincenootherorganisationhasimplementedthestandardbefore.
TheEnMStrainingallowedtheTennecoteamtodevelopanenergymanagementsystemalignedwithTenneco’sneeds.Thiswasachallengingtask,aswhileassistancewasavailabletoimplementanenergymanagementsystem,adaptingtheEnMStoISO50001provedmoredifficult.
19
IMplEMEntED SaVInGS MEaSURESThefollowingtableshowsenergysavinginterventionsimplementedwithcommensuratecostsandsavings.
cOnclUSIOnFutureworkwillincludepowerfactorcorrection(PFC)asthiswasleftuntillaterintheprogrammetoreducetherequiredsizeandcostoftherequiredPFCequipment.Paintshopmodificationswillonlybemadetocoincidewiththenewpaintshopdesignthatisplannedfor2015.
Intervention (all project groups have been combined)
capital costZaR
SavingsZaR
paybackYrs
Energy saving
CompressedairsystemsCompressedairoptimisation
R1023265.30 R425595 2.4 766305kWh
LightinginitiativesFactory,Offices,Sensors,DaylightHarvesting
R1076695.40 R780131.49 1.38 926064kWh
Paintshopburnersubmersiontube R35000 R16284 2.14 15366kWh
Automaticmetering.Electricity,LPG,Shieldinggasweight
R149011 – – Betterenergymanagement
NewChromePlantingoven R750000 R634508 1.18 829444kWh
PowerFactorcorrectionatTenneco–EmissionControl.TobedoneatTenneco–RideControl
R69079 R142776 0.48 127kVA
Procedures–Shutdown,SEUtraining – – – Betterenergymanagement
tOtal R 3 103 050.70 R 1 999 294.49 2 537 179 kWh
ThecompanybelievestheimplementationoftheEnMSwouldhavebeeneasiertounderstandiftheISO50001standardwasconsideredfromthestart.Toensuresustainabilityofthesystem,allnewequipmentwillcomplywiththeinternalenergyefficiencyregulations.TennecohasfoundthatthecompanyculturehasbenefitedfromtheIEEprojectinthatmoreteammembersareawareofandactivelyengagedinenergysavingsinitiatives.
Highlights of operational/ESO interventions
kEY FInDInGS: Thetwoplantscompletedmorethan15projectsofvaryingsizesoverthreeyears.R3 100 000 was investedwithapaybackperiodof1.55years.Monetarysavings amounted to R2 million,energy savingsamountedto2 540 000 kWh,andGHG emissionwerereduced by 2 428.08 tonnes of cO2.
caSE StUDY
20
Automotive component suppliersJOHnSOn MattHEY SOUtH aFRIca
BackGROUnDJohnsonMatthey,aBritishcompanyestablishedin1817,isaglobalmanufacturerofautomotivecomponents,specificallyautocatalysts.TheSouthAfricanoperationbeganin1953andsince1992JohnsonMattheySouthAfrica(JMSA)hasbeenmanufacturingcatalystsatitsGermiston(Gauteng)plant,supplyingseverallocal“canners”whofitthecatalystintothecatalyticconvertersystemforexporttothemotorvehicleassemblers.
Inresponsetotheincreaseinenergycosts,JMSAGermistonsignedupwiththeIEEProjectin2012asacandidateplantfortheimplementationofanISO50001-basedenergymanagementsystem.TheplantholdsmanagementsystemcertificationforISO9001/TS16949,ISO14001andOHSAS18001andadoptedtheISO50001approachasanintegrationandextension.
IMplEMEntatIOn OF an EnERGY ManaGEMEnt SYStEM AnIEEProjectenergyconsultantfacilitatedasystemsreviewandconductedanISO50001initialaudit.TheexpertthenassistedJMSAtodevelopandimplementanenergymanagementsystem(EnMS)andenergyefficiencymeasuresweresystematicallyimplementedinbothproductionandutilities.
Existingstructures,suchaspolicies,proceduresandsustainabilityreporting,wereexpandedtoincludeenergyspecificrequirements.
Anenergyteamwasappointed,underthechairmanshipoftheEngineering(Energy)Managerwhichmetweeklytoidentify,co-ordinateandimplementenergyperformanceimprovements.TwomembersoftheenergyteamattendedtheIEEProject’sadvancedEnMStrainingandfurthertrainingisplannedforadditionalenergyteammembersandenergymanagementsystemauditors.
HIGHlIGHtS OF IntERVEntIOnSFourmainprojectswereidentifiedaspotentiallylargeenergysavers.Threeofthese,namelytheaircompressors,chillersandmixingvessels,couldbeimplementedimmediatelywithnominalornoinvestmentrequired.
Thefourthprojectwastheoptimisationoftheovens,whichwasimplementedasphasetwo,duringtheDecembershut-downperiod.
ThesefourprojectsresultedinapproximatelyR4.5millionoftheR7.7millioninsavings.Thebalancewasrealisedthroughbehaviourchangesandaprocessofcontinuousimprovement(Kaizenprojects).Asummaryoftheinterventionsandsavingsrealisedisoutlinedinthetableopposite.
key findings
Totalnumberofprojects
FourlargeandvarioussmallKaizenprojects
Monetarysavings
Totalsavings R7,728,569
Fourmainprojects R4,540,098
Balance R3,188,470
Energysavings
Totalsavings 9,425,084 kWh
Largeprojects 5,469,998kWh
Balance 3,888,379kWh
Totalinvestmentmade R620,000
Paybacktimeperiod 1 month
GHGemissionreduction 9,020 tonnes of cO2
21
SUMMaRY OF all IntERVEntIOnS
cHallEnGES anD lESSOnS lEaRnED
• Behavioural changes –variouscommunicationandsuggestioncampaignswererunandtheenergyawarenessincreased.Itiscriticaltoensurethatenergyinfluencersunderstandtheenergyimpactsoftheirworkandactions.
• Measurement/metering –itisimportanttohavesufficientmetering,andtoensuresubmetersonsignificantenergyuserstoallowforaccuratemeasurementandbetterinformfutureimplementation.
• Selection of correct energy team members –selectingthecorrectindividualsandrepresentationofalltherelevantsectionsoftheplantiscriticaltodriveandEnMS.Itisadvisabletobewillingtomakechangeswherenecessaryandtoensuresignificantinvolvementbyproductionpersonnel.
• knowledge and awareness –thisprocessshowedthecriticalnatureofbecomingawareofthepotentialforenergysavingsandhowtorealisethemeffectively.
• attitude is of paramount importance.
System Intervention capital cost ZaR
Energy saving Savings ZaR (average of R0.82/kWh)
Compressors Reducewaste–repairedleaks,increasedawarenessandoptimalusageoftheequipment
Zero 1,072,163kWh R879,174
ChillersR20,000 933,973kWh R765,858
Productionmixingvessels
Identifiedareasofwaste–vesselsleftrunningwhenproductionlineswerestopped.Introducedalockoutsystem.
Zero 2,180,862kWh R1,788,307
OvenOptimisation
•Shutdown3De-humidifierunitsbyre-routingtheair
•Re-circulationratioincreasedto~50%-60%
•Allfancowlingswerecooledandinsulationwasreplaced
R600,000
1,283,000kWhyearonyeardespitea9.73%
increaseinrunningtime
R1,065,000
Otherprojectsandfactors
Behaviourchangese.g.switchingequipmentoffwhennotinuse)
Focusonproductionefficiencies
Kaizenprojects
Zero 3,888,379kWh 3,188,470
The Johnson Matthey energy team outside the Germiston plant following the handover of their ISO 50001 certificate by a UNIDO and SABS delegation in April 2014
caSE StUDY
22
BackGROUnDFeltexAutomotiveTrimLtdisaleadingsupplierofawiderangeofqualityautomotiveacousticandtrimcomponents,includingcarpets,variouscompartmentinsulators,parcelshelvesandwheelarchinsulators.OneoftheirplantsislocatedinJacobs,DurbanSouth,KwaZuluNatal.
Heatisusedinvariousstageswithinthemanufacturingprocess,includingheatingandformingoffibresheetsunderpressure,andpre-heatingofmaterialsusedinfloorcarpetmanufacturebeforelayeringandpressingviabanksofheatingelements.Pressmouldingsarewatercooledviaacentralisedchillersystem,andfumesproducedintheprocessareextractedviahoodandextractorfansystems.Certainproductsaretrimmedusinghighpressurewater-jetcuttingunits.Compressedairissuppliedviaacentralisedcompressor,andlightingisprovidedbyfluorescenttubes.
FeltexDurbanunderwentanenergyauditinFebruary2012aspartoftheNationalCleanerProductionCentreofSouthAfrica(NCPC-SA)’sResourceEfficiencyandCleanerProductionProgramme.ThepurposeofthiswastohelpFeltextocharacteriseenergyusage,determineSignificantEnergyUsers(SEU’s),andtoidentifyopportunitiesforenergyconsumptionreductionwithintheplant.Theauditidentifiedtheneedtoaddressenergymanagementsystemswithintheplant,andarecommendationwasmadetostrengthentheenergymanagementcapabilitiesoftheplant.
ThispromptedFeltextoadoptanEnergyManagementSystem(EnMS)throughtheIndustrialEnergyEfficiency(IEE)Project,asimplementedbytheNCPC-SAinconjunctionwithUNIDO.Feltex’scompanyengineerattendedtheIEEExpertLeveltrainingfromNovember2012andsuccessfullycompleteditinNovember2013.ThispromptedthedevelopmentofanenergypolicyintheearlystagesoftheEnMSprogramme.
TheendorsementofandcommitmenttotheprogrammebyFeltex’stopmanagementwasakeycontributortosuccess.
IMplEMEntatIOn OF an EnERGY ManaGEMEnt SYStEM Anenergypolicywasdraftedandadopted,andanenergyteamwasestablished.Eachmemberoftheteamwasassignedspecificresponsibilitiesandgivenclearmandatesregardingutilityefficiencyandenergymanagement.Adecisionwastakentoimplementmandatorytargetedtrainingforallenergyend-users.Tothisendaneedsanalysisandskillsassessmentweredonetodeterminethecontentofthetraining,andcontentspecifictodifferentfunctionswasdeveloped.
IMplEMEntatIOn cHallEnGESThedeterminationofakeydriverastheprimaryinfluenceonthelevelofenergyusageandagainstwhichperformancecouldbemeasured,provedchallengingasthedevelopmentofarealistic
Vehicle Component Supplier FEltEX aUtOMOtIVE tRIM – DURBan
key findings / savings table
ImplementationPeriod 2013to2014
Numberofprojects 6
EnergysavingsinKWh 1,070,000kWhperannum
Paybackperiodinyears <12months
GHGEmissionReduction(tonCO2e) 1,024tonnesCO2
23
baselinewasdifficult.Amorerigorousmeterreadingprocedure,combinedwithaspecificweeklyproductionmonitoringinitiative,meant
SUMMaRY OF IntERVEntIOnS
thattherelationshipbetweenproductionandenergyusagecouldbemodelledusingregressionanalysistechniques.
System Intervention Energy saving per year
Tacamouldingsectionpresses Thermalinsulationofthepresshousingstominimiseunnecessaryheatwastagetoatmosphere
140,000kWh
Autolinepressandchillersystems(twoprojects)
Insulationoftheheatingplatetominimiseunnecessaryheatlosstoatmosphere
Insulationofsuction-sidepipeworkontheAutolinechillersystem
18,500kWh
Lightingretrofit Replacementofdatedfittingswithmodernequivalents;moreappropriateswitchingarrangements;makingoptimaluseofdaylight.
732,000kWh
Compressedairprogramme Optimisingcompressedairusagethroughemployeeawareness;reductionofconsumptionatpointofuse;optimisationofsystemincludingleakagereduction;replacementofcompressors.
44,100kWh
Unusedequipment Switchingoffunusedequipment 135,400kWh
lESSOnS lEaRnED
• leadership supportatalllevelsoftheprogrammeisaprerequisite.
• composition of energy team shouldinvolvepeoplefromawiderangeofbackgroundsandskill-sets.
• analysis of key data(productionandenergydata)isvitalintheidentificationofopportunities.
• Many opportunitiesexistforenergysavingwithlittleornoimplementationcost.
• linking of data isvitaltolinkthebusinesscasetokeybusinessdriversandtohighlightanyadditionalbenefitsthatthecompanymayderivethroughtheuptakeofenergymanagementbestpractice.
caSE StUDY
24
BackGROUnDFeltexAutomotive,headquarteredinDurban,consistsofsevenbusinessunitsthatsupplyproductsdirectlyandindirectlytoSouthAfricanOriginalEquipmentManufacturers(OEMs).
TheFeltexAutomotiveTrimplant,locatedinRosslynPretoria,isaleadingsupplieroftextile-basedautomotiveacousticandtrimcomponents.Itproducestechnicalfeltsinneedledandairlayconstructionsandnon-wovencarpets(bothstructuredandconventional)inabroadrangeofweights,widthsandspecifications,formouldableapplications.Fromitsfactoriesdirecttocustomers,FeltexTrimsuppliesmainfloorcarpets,passengercompartmentinsulation,trunkpackages,enginecompartmentinsulation,parcelshelvesandexteriorwheelarchliners.
Mostoftheprocessesrequirethefollowingactivities:
• Heatingofmaterial.Theheatingismainlysuppliedbyelectricity.
• Mostoftheequipmentrequirescompressedairforoperation.Althoughtwocompressorsareinstalled,onecompressorisoff-lineduetovariousimprovementstothereticulationandrequirementsforcompressedair.Compressedairiscurrentlysuppliedthroughone75kWcompressor.
tHE ISSUE anD MaIn FInDInGSInordertotransformoperationalprocesses,reduceenergyconsumptionandcosts,andensurelong-termenvironmentalsustainability,FeltexTrimjoinedtheIEEProjectin2012andtheFeltexTrimRosslynmaintenancemanagersignedupforEnMSexpertleveltraining.
Vehicle Component Supplier FEltEX aUtOMOtIVE tRIM – ROSSlYn
kEY FInDInGS:(2012-13)Nocapitalinvestmentandjustanin-housecostestimatedatR30000inlessthanoneyearrealisedanannual saving of R 287 451.Energy savings of 309 087 kWhwithaconcomitantGHGreductionof295796tonnesCO2.
(2013-14)AfteraninvestmentofR197600,asaving of R 99 519withapaybackof1.98yearshasbeenrealised.A215 611 kWhand213 tonnes cO2 reduction per yearwereachievedaswellasadditional energy conservation opportunities identified.
25
In2012,twomainprojectswereidentifiedasESOinterventions:
• platten Heater:Theprocessofshapingcarpetsunderheatrequiresbothheatandpressure.Itwasfoundthatequipmentwasnotoptimallyutilised,withroughly50%oftheheatingsurfaceoutofcontactwiththeproduct.Mouldswerere-casttogetclosertothe100%target.Asaconsequence,productionwasalmostdoubledwithoutapplyingadditionalheat.Theresultingspatialtargetachievementalsohalvedproductiontime,reducingelectricityconsumptionby50%.
• Electricity to heat products: wasteheatwasreroutedtopre-heatproductsbeforereachingtheoven,therebyreducingthe75°Coventimefrom90to45seconds.Acanopywasconstructedtocapturethelostairwhendoorswereopenedanduseitforpre-heatingproducts.Thisinterventionhalvedoventimeandconsequentlyelectricityconsumptionbyabout45%.
Inaddition,thefollowingstepsweretakenin2012/13:
• Staffenergyawarenessinterventions:erectingpostersdisplayingdryingovenenergyconsumption.
• Equipmentandsoftwarewasinstalledtomonitordryingtunnelenergyconsumption.
• Permanenttrackswereinstalledinthedryingovenstoensurenotrolleymovementallowinghotairtoescape.Theinstallationalsoresultedinareductionofdryingtime,from24hourstoaround19hours.
• Flapswerealsoinstalledtorestrictairflowthroughthepansoffruitbeingdried,avoidingthelossofhotairinunutilisedareas.
• Staffbehaviouralchanges:toensurethatthedryingtunnelswerebeingoptimised,staffwastrainedtoaddthemaximumamountsofpanspersession,reducingkWhusageperpanandoptimisingproduction.
EnERGY cOnSERVatIOn OppORtUnItIES IDEntIFIED 2012-14
caSE StUDY
26
• Thetotalamountofenergyconsumedbytheovenswasreducedbyabout20%.
• Automatingthefourcoldstoredoorsandretrofittingremotecontrolstoforkliftsensuredlesswastefultemperaturelossduetodoorsleftopenindiscriminatelyduringpackingoverproducefortransporttoend-user.
During2013/14,thefollowingopportunitieswereidentified:Therequirementforcompressedairthroughouttheplantoverweekendswasassessed.Itwasfoundthatatthefoamingplantcompressedairwasneededtocirculatethefoaminthestoragetank.A2.2kWcompressorsupplyingairat3Barwasinstalled.Thismadetheoperationofthemain75kWcompressorat6Baroverweekendsredundant.
Carpetsareheatedbeforetheyarepressedintherequiredshape.Thetraditionalwayofheatingthecarpetswastouse36resistiveheaterelementsratedat2kWeach.Theseheaterstakealongtimetoheatupandconsequentlyarenotswitchedoffbetweencarpets.Theywerereplacedwith48infraredheatersratedat1.5kWwhichheatupinstantaneously.Controllersoftheprocesswerereprogrammedsothattheheatersonlyswitchonwhenthereisacarpetinthemachine.Thetimerequiredintheovenalsoreducedfrom80secondsto45seconds.
Heatedairisusedtopre-heatcarpetsbeforetheyaregluedandpressed.Airisheatedthrough36elementsratedat1kWeach.Previously,thecarpetswereconveyedintotheovenonagridconveyorandthehotairby-passedthecarpetandfollowedthepathofleastresistance.Consequentlythecarpetstooklongertopre-heattotherequiredtemperature.Bufferplateswereinstalledtocontrolairflowsothatheatisefficientlyappliedwhereitisrequired;onthecarpet.Theresultisthatcarpetsarenowpre-heatedwithin45secondscomparedto90seconds.
Inasectionoftheplant,thecorrugatedroofplateswerereplacedwithtranslucentroofplatestomakeuseofnaturallightinsteadofartificiallightduringtheday-shift.Thisresultingin50highbaylampsratedat125Wbeingswitchedoffbetween18:00and6:00wheretheywerepreviouslyoperational24-hours.
lESSOnS lEaRnEDFeltexTrimRosslyndemonstratedthatsubstantialenergysavingscouldbeachievedwithoutmajorcapitalinvestmentorretrofitting.Byjustchallengingthestatusquoofoperationsandpro-activeactiontowardsoptimaloperation,asubstantialimpactwasachievedonbothproductionthroughputandelectricityconsumption.
Vehicle Component Supplier FEltEX aUtOMOtIVE tRIM – ROSSlYn
(continued)
27
HIGHlIGHtS OF ESO IntERVEntIOnS
System Intervention Investment ZaR
Savings ZaR
payback period
Energy saving (kWh)
GHG Emission
Reduction (kg cO2/
year)
PlattenHeater
Optimalusageofheatedareasintheequipment
15,000
287,451 <1yr 309,087 295,796
HeatingOvenWasteheatrecoverytopreheatproducts
15,000
Compressor
Installationofsmallaircompressortosupplyweekendload
10000 36700 0.27yrs 101192 100000
HeatercoilsReplaceresistiveheatercoilswithinfraredlamps
57600 33770 1.7yrs 61401 60000
Bufferplates
Bufferplatesatline2manufacturedin-housetomatchcarpetsizes
0 19356 0 35193 34800
Lighting Useofnaturallight 130000 9693 13 17625 17000
caSE StUDY
28
BackGROUnDToyotaBoshokuSA(Pty)Ltd(TBSA)isasubsidiaryofToyotaBoshoku,basedinJapan.TBSAisbasedinUmbogintwini,KwaZuluNatal,SouthAfricaandmanufacturesdoorpanelsandcarseatsforToyotaSouthAfricaMotors.Thefacilityishousedinonelargebuilding.
TBSAisanISO14001accreditedcompanyandthereforehastoshowcontinuedimprovementwithregardtoenvironmentalchallengesasrequiredbytheplantandassetoutintheToyotaBoshokuGlobalObjectivesandTargets.TBSAalsostrivestoachievethenationalenvironmentaltargetsaswellasrequirementsoftheircustomer(ToyotaSouthAfricaMotors).
OVERVIEW OF IMplEMEntatIOn TBSA’sSectionManager–GeneralAffairsattendedaDurbanAutomotiveClusterworkshop,whichintroducedtheprogrammetoToyotaBoshoku.
AnIEEProjectassessmentwasconductedattheplant.Theinterventionsdealtprimarilywiththereplacementofexistinglightingtechnologieswithnew,energyefficienttechnologiesasrecommendedintheassessmentreport.
Automotive Industry Parts ManufacturertOYOta BOSHOkU Sa (ptY) ltD
HIGHlIGHtS OF ESO IntERVEntIOnS Atotalof874oldtechnologylampswithconventionalballastswerereplacedwithenergyefficientlampswithelectronicballasts,resultinginanaveragemonthlyenergyconsumptionsavingof15,86kWh.Timerswereinstalledtoswitchoffselectedinternallightfittingsduringdaylighthours.Replacementsweremadeasfollows:
• ReplacementoflinearlampT8lightfittingswithlinearlampT5fittings;
• ReplacementofHIDfloodlightfittingswithCFLlightfittings;and
• ReplacementofHalogenlampswithLEDlamps.
Existing technology Quantity new technology
Energy saving (kwh)
GHG Emission Reduction
(kg cO2/year)
DoublelampT8fluorescentlightfittings
846 Replacedwithnewdoublelamp28Wfluorescentlightfittings
153,408 151,873
50WHalogendownlightlamps 5 Replacedwithnew5WLEDlamps
819 811
400WHIDfloodlightfittings 21 Replacedwithnew105WCFLfloodlightfittings
34780 34,432
250WHIDStreetlightfittings 2 Replacedwithnew105WCFLstreetlightfittings
1638 1,622
The above was in addition to the replacement of and control of the HID Highbay lighting which was completed before the energy assessment.
kEY FInDInGS:Oneprojectwas
undertaken,resultinginasaving of
190,645 kWh andR 165,203 per yearfor
aninvestment of R 451,840(payback
periodof1.85years).Areduction in
GHG emissions of 188,738 kg cO2
wasachieved.
29
IMplEMEntatIOn cHallEnGESLabourstrikesandholidayshutdownsprolongedtheimplementationoftheprogramme.Furtherdelayswerecausedbyproblemswiththesupplyofproductsneededtocompletetheproject.
lESSOnS lEaRnED
• Energysavingsarepossiblewithoutmajorcapitalinvestment.
• TheToyotaBoshokuGroupalreadyhadpoliciesinplacetoimproveandreduceenvironmentalimpact.TheIEEProjectfittedwellintotheexistingculture.
• ToyotaBoshokuwasimpressedwiththeconductandefficiencyofIEEProjectstaffandconsultants.
30
WiththesupportoftheAIDC,theIEEProjectwasabletoengageSMEsintheautomotiveandrelatedsectorsandoffertechnicalreportsandrecommendationsonenergyefficiencyinterventions.
However,theIEEProjectiskeenlyawareoftherealchallengesfacedbySMEswishingtoimplementEnMSorevenESOinterventions,despiterisingenergycosts.
“ItisoftendifficultforSMEstoseethelong-termvalueofimplementinganenergymanagementsystem.Byitsverynature,anSME’sownermightalsobethemarketerandfulfilotherresponsibilities,makingitdifficulttotakemoretimefromabusyscheduletofocusonenergymatters.
“Theruleofthumbforappointingadedicatedenergymanageriswhenthecompany’senergycostsreachorexceedR100millionperyear,”explainstheIEEProject’sAlfHartzenburg.
But energy savings are possible, even for SMEs with limited internal capacity.
BentelerAutomotiveinUitenhage,EasternCape,tookupthechallengeandisstillpartoftheIEEProjectwithleadershipnotonlyappreciatingtheneedtoimproveenergyefficiencybutalsotakingastrongleadinensuringthecompanyremainscommitted.
TheTechniplateandPrecisionPresscasestudiesonthefollowingpagesoutlinetheeffortsoftwoSMEsintheautomotiveandrelatedsectors.
“Manycompaniesaresurprisedtohearthattheydonothavetospendmoneytosaveenergy.Itisnotnecessarytoinvestintechnologyupgradestoeffectenergysavings.Infact,somecompaniesusethemoneytheysavethroughtheirenergymanagementsystemtofundtechnologyupgrades,”saysHartzenburg.
The IEE Project and small, medium and micro enterprises
OneoftheservicesofferedbytheIEEProjectisfreeenergyauditsforsmalland
mediumenterprises(SMEs).
Intheautomotivesector,thisprocesswasassistedgreatlybythestrategicpartnership
betweentheNationalCleanerProductionCentreofSouthAfrica(NCPC-SA)and
theAutomotiveIndustryDevelopmentCentre(AIDC).
Percentage of assessments within each sector
23%
15%
13%
10%
5%4%
29%1%
Agro-processing
Automotive
Chemicals,Plastics&Pharmaceuticals
MetalAlliedsandEngineering
Manufacturing
PaperandPulp
Clothing&Textile
Other
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IEE pROJEct – SME EnERGY EFFIcIEncY aUDItSSince2011,theIEEProjecthasconducted227energyaudits.51ofthese(23%)wereintheautomotivesector.
Throughtheseaudits,potentialenergysavingsof108GWhwereidentified,valuedatsomeR101.5million.
Percentage of potential energy savings identified in each sector
potential savings identified through energy audits in SMEs
Sector Rands/annum % (R/a) kWh/annum % kWh/a
Agro-processing 50394755 45% 48106764 44%
automotive 13 928 814 12.4% 11 052 155 10%
Chemicals,Plastics&Pharmaceuticals 13727194 12% 14906851 14%
MetalAllied&Engineering 21887111 19.6% 27276480 25%
Manufacturing 3877385 3% 875581 1%
Pulp&Paper 292799 – 139181 –
Clothing&Textile(CTFL) 3135224 3% 1626031 1%
Other 4354973 4% 4847573 4%
tOtal 111 598 255 108 830 617
Ofthese,10%oftheenergysavingsidentified(11GWh)wereinautomotivesectorSMEs,withover12%ofthemonetaryvalueoftheenergysavingsbeingwithinthissector. (The discrepancy is due to the different energy sources used and the relative cost of these energy sources.)
Agro-processing
MetalAlliedsandEngineering
Chemicals,PlasticsandPharmaceuticals
Automotive
Other
ClothingandTextile
Manufacturing
44%
25%
14%
10%
4%2%1%
caSE StUDY
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tHE ISSUE anD MaIn FInDInGSTechniplateElectroplatersislocatedinSilvertonPretoriaandoffersarangeofplatingproductsandservices,includingelectro-polishing,embossing,etchingandcolouring.Inthedeliveryoftheseservices,thecompanymakesuseofplatingtankswhichoperateatextremelyhightemperatures,resultinginhighenergy(specificallyelectricity)consumption.
Consumptionstatisticsshowedthatthetotalamountofenergyusedbythesitewasequalto2,186,708kWhperannum,atacostofR735202.
EnERGY cOnSERVatIOn OppORtUnItIES IDEntIFIEDAnIEEProjectenergyauditidentifiedthatTechniplate’splatingtanks’temperaturewasbeingmanuallycontrolled,therebyresultinginhighdegreeoftemperaturevariations,excessivetemperaturesandexcessenergyuse.
Recommendation:Plating Tanks Auto Temperature Control (ECO1)
IMplEMEntED SaVInGS MEaSURES
MeasurementanddataanalysisDatameasurementsclearlyshowedthatwhenautotemperaturecontrolison,energyconsumptionwassignificantlylowerthanwhenautotemperature
controlisdeactivated.Thedifferenceintheaverage(mean)energyconsumptionis1.9kWh.
Boththemeanandthemedianoftemperaturearehigherwhenthereisnoautocontrol.Thedifferenceofthemeansshowsthatwithoutautocontrolthetanksarerunning4.7 ° c hotter.Temperaturevariabilityasindicatedbythestandarddeviationis6.5morewithoutautocontrol.Thishighvariabilitymighthavequalityconsequencesontheproduct.
Plating Tank Temperature ControltEcHnIplatE
parameter Energy consumption temperature control
auto control
Manual control
auto Manual
Mean 5.3kWh 7.2kWh 50.4°C 55.1°C
Median 5.2kWh 7.0kWh 50.5°C 56.2°C
Min 4.2kWh 5kWh 49.8°C 49.6°C
Max 7.2kWh 9.4kWh 51°C 57.2°C
Range 3kWh 4.4kWh 1.2°C 7.6°C
StDeviation
0.76 1.88 0.44 2.85
Summary Statistics of the Measurement Data
The temperature controller
used for this case study.
Both this item and the
energy meter also used in
the case study cost R 1100.
kEY FInDInGS:AfteraninvestmentofR46,200,asaving of R 172,751 (23.5% saving)withapaybackof4monthshasbeenrealised.Energy savings of 421 344 kWh (19.3%saving)achieved.
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DEtERMInatIOn OF SaVInGS anD paYBack pERIODBelowisthecalculationoftheenergycostsavingsandpaybackperiod.
PaybackPeriod:• Totalcostofinstallationfor42tanks=R46,200• Paybackperiod(46,200/17,251)=4 months
Thetemperatureprofileoftheplatingtanksisalsofarmorestablewithautocontrolthanwithoutit.Whenoperatingonautocontrol,thevarianceisaslowas1.2°Cwhilewithoutautocontrolthetemperaturehasawiderangeof7.6°C.
Theplatingtankenergyconsumptionprofileforbothautoandmanualcontrolalsoshowsthatwithout
Energy and cost Saving
CostperkWh R0.41perkWh
Noofplatingtanks 42
Totalenergyusedperyear 2186708kWh
Costofenergyconsumedperyear R735202
Energysaving(determinedfromdifferenceofmeansfromtable4) 1.9kWh
Workinghoursperyear(24x4+14)x48 5280hrs
Totalenergytobesavedperyear(5280hrsx1.9kWhx42tanks) 421 344 kWh
Percentageofenergysaved 19.3%
Costofenergysavedperyear(421344kWhx0.41) R 172 751
Percentageofcostssaved 23.5%
cOnclUSIOnThissimpleenergy-savingmeasureresultedinasavingof19.3%ofenergyand23.5%oftheenergycostsofthisSME.Inaddition,theinvestmentwaspaidbackintherelativelyshorttimeframeofonlyfourmonths.
Anotherbenefitofthemeasuresisbetterprocesscontrol,whichmayresultinbetterproducts.
autotemperaturecontrolenergyconsumptionishigher.
Atemperaturecontrollerandanenergymeter(shownleft)wereinstalledateachplatingtankatacostofR1,100each–atotalcostofR42,600.
caSE StUDY
34
tHE ISSUE anD MaIn FInDInGSprecision press isamedium-sizedmetalpressingautomotivepartsmanufacturerwhichmanufacturesawiderangeofautomotivepartsandcomponents.Ithas163employeesandisbasedinCapeTown.
Duetothenatureofthemachinesandprocessesusedtomanufacturetheparts,technologicalsolutionswereveryexpensive,andfocushadtobeplacedonsystemsandprocedurestoreducetheelectricityusageandbringthemaximumdemandenergyusagedown.
EnERGY cOnSERVatIOn OppORtUnItIES IDEntIFIED Aprogrammeofenergyefficiency(andotherresourceefficiencyconsiderations)wasinitiatedinorderto:
1. Createsustainableenergyefficiencyawarenessamongstallemployees.
2. Reducethecompany’selectricitybillby20%.
BasedontheresultsofaSWOTanalysisandanIEEProjectassessment,opportunitiesforinterventionwereidentifiedasfollows:
Energy systems optimisation in an SMEpREcISIOn pRESS
Objective Description Implementation timeframe
Subproject 2:Switchingoff–hydro-boils,lights&motors(presses)whennotinuse
1months
Subproject 3:Compressedair–leaktagging,awareness&sustainablesystem
1months
IMplEMEntED SaVInGS MEaSURES
capital cost ZaR
Savings per annum
ZaR
payback Months
Environmental benefit per
annum
Switching-offelectricalequipment 793.20 37,699 0.25 55,000kWh
RepairingCompressedairleaks 0 28,566 - 62100kWh
total 793.20 R66,265 0.14 117 100 kWh
kEY FInDInGS:Byrepairingcompressedairleaks,atnocosttothecompany,androllingoutanawarenesscampaignatacostofonlyR793,energy savings of 117 100 kWHwithavalueofR 66,265 p/year wererealised.Theoverallpaybackperiodwas0.14months.
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Energy systems optimisation in an SME
SWItcH-OFF caMpaIGn Duringweekendsabaseloadwasmeasuredofaround30kW.Thiswasduetolightsandelectricalmachinerybeingleftonduringnon-productionhours.Automatictimerswereinstalledonthehydro-boilstoswitchthemoff.Foritemsthatcouldnotbeautomatedduetoflexibleoperatinghours,employeessuchasteamleadersandsupervisorsweregiventheresponsibilityofensuringmanualswitch-off.Awarenessposterswereplacednearoronallswitchesandmachines.Theswitchingoffprojecthasreducedtheelectricityusagebyanestimated55,000kWh,whichamountstoacostsavingofR37,699.
cOMpRESSED aIR Airleaksfrequentlyoccurduetheheavyvibrationofthemachineryduringtheproductionprocess.Inthissub-project,allairleaksweretaggedandapolicysetuptoensurethatairleaksarefixedeverymonth.Compressedairwasalsobeingusedtoblowfinishedpartsfromthemachineintothefinishedgoodsbins.Thiswasdoneforconvenienceandtheoperatorswereunawareofthehighcostsinvolvedincompressedairusage.Alternativemechanicalsolutionswereimplementedandtheoperators’awarenessestablished.Thishasproducedasavingof62100kWh,whichamountstoacostsavingofR28566.
cOnclUSIOn Asuccessfulandsustainableenergyefficiencycampaignrequiresallemployeestobeinvolvedandawareofthecostimplicationsonoperationalexpenses.ThelevelofcommitmentandsupportfromthemanagementatPrecisionPressmadethetaskeasier.PrecisionPresshasimproveditsenergyawarenessanditcanbeseeneverywhereinthefactory.ThisaddsvaluetotheclientandimprovesthecompetitivenessofPrecisionPress.
The inappropriate use of compressed air as it was used to blow parts out of the press. This cost the company an estimated R5000.00 annually
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