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Niall Aughney (I2E2) & Dr. Garret O Donnell (TCD)

Niall Aughney (I2E2) & Dr. Garret O Donnell (TCD). Lean energy- optimising energy consumption  in manufacturing processes and process chains Becoming lean- the practical route to competitiveness, May 11 th Dublin Castle, Ireland. Lean Principles – preaching to the converted!.

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Niall Aughney (I2E2) & Dr. Garret O Donnell (TCD)

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  1. Niall Aughney (I2E2)&Dr. Garret O Donnell (TCD) Lean energy- optimising energy consumption  in manufacturing processes and process chains Becoming lean- the practical route to competitiveness, May 11th Dublin Castle, Ireland

  2. Lean Principles – preaching to the converted! • There are 5 principles that underpin Lean thinking • Value • Specifically what is value from the customers perspective • An energy viewpoint: ‘how do we deliver this value with optimum energy consumption’ • Value Stream • What is the sequence to deliver from start to finish the product or service that the customer values • An energy viewpoint: ‘Can we map energy consumption of the process that the customer values’ • Continuous Flow • This value must be then delivered without interruption • An energy viewpoint: ‘How can this value be delivered without interruption but with minimum energy consumption’ • Pull • Products or services must only be produced when the customer requires them • An energy viewpoint: ‘How can our process deliver only what the customer requires with minimum energy consumption’ • Perfection • These products or services must be continuously improved • An energy viewpoint: ‘How can we further reduce our energy consumption without compromising our customer’

  3. Muda: How do you identify waste?

  4. Why Expand Lean to Energy? • Lean Principles are robust • Lean Principles are applicable to many different business processes & industries • Lean Principles are simple to understand • Lean Principles train personnel to identify ; • Value Added Activities • Non Value Added Activities • Necessary Non Value Added Activities • Lean Principles are proven at reducing costs within processes • ‘All we are doing is looking at the timeline. From the moment the customer gives us an order to the point when we collect the cash. And we are reducing the time line by removing the non value added wastes’ – Mr. Taiichi Ohno, TPS – Beyond Large Scale Production. • But Energy is consumed within this timeline • Lean Principles can be applied to understanding this energy consumption • Most ideas start with a need – ‘can we reduce our costs in light of the current energy crisis?’……..it was an oil crisis in 1973 that made people take Lean more seriously….how times have changed!?

  5. Irelands Current Electricity Generation by Fuel Type Figure 1: Graph of Electricity Generation by Category in Million Tonnes of Oil Equivalent (Mtoe). Source: SEAI. • Currently Ireland is heavily reliant on oil to generate electricity • Although this may change in the future based on technology developments • Our exposure to international oil prices has a an impact on our cost base, the higher the price the more challanging it is to do business • By investigating ways to be more fuel efficient, we can affset these rises

  6. The knock on consequence to business…… Figure 2: Industrial kWh pricing within the EU. Source: EuroStats • Electricity costs can account for the majority of a factories utilities bill • Our electricity costs are rising…and impacting our cost competitiveness • We need to offset this rise with improved energy efficiencies • Can we do more with less? Can we use less?

  7. DMAIC – A tool to characterise consumption • Exergy analysis of compressed air in industrial consortiums in Ireland 42% 13% 8% 33%

  8. I2E2: Who we are Vision: To be a Centre of Excellence in Ireland which is recognised as a European and global leader in directing energy research and innovation for manufacturing industry in the areas of efficiency, management and sustainability Mission: To identify, drive world-leading research and innovation to help Irish manufacturing companies to reduce, on a sustainable basis, both the cost and associated environmental impact of their energy use Membership:

  9. I2E2: Who we are • Strategic objective is to develop an ‘embedded’ manufacturing research and development program to enable high technology companies in Irl & Europe to deliver • Breakthrough solutions in Energy Efficiency • Enhance business asset portfolio for MNCs • Enable Growthof SMEs, Start Up high tech growth • Manufacturing innovation - an enabler for future investment • Neutralising cost as a disabler for future investment

  10. The Research Lifecycle Where do ICMR and I2E2 Fit In ! Applied Research in Academia Solutions Products HPSU Blue Sky Research in Academia

  11. The Research Lifecycle - Where does I2E2 Fit In 5yr+ 1-3yr Platform for HPSU 2-5yr ! Applied Research in Academia Industry Solutions HPSU Embedded Research in Industry Blue Sky Research in Academia Scoping of research. ID RPOs, funding Partnership with industry. WP owners Partnership with industry. WP owners Industrial challenges identified

  12. I2E2: Who we are • We are focused on applied research within an industrial setting • We are focused on delivering breakthroughs in energy efficiencies to enhance members competitiveness • Using Lean & 6-Sigma methologies as appropriate • We are focused on MNE & SME manufacturing based organisations on the island of Ireland • We want to use some of the research capabilities of the state to specifically work on our members issues • Research teams consist of industrial engineers & academic researchers • Placed in industrial environments • Working on solutions to problems defined by industrial members

  13. I2E2: Project involvement to address strategic needs (3-5 yr timeframe) • Appropriate Working Environments: Focus on energy reduction by researching, developing and application of new technologies to support Heat, Ventilation and Air Conditioning (HVAC) systems in Manufacturing plants. • Lean Language: ‘Jidoka’, ‘Autonomation’ or Condition Based Monitoring • Low Grade Heat Recovery: Development of techniques to optimise the use of flue gas heat recovery in a cost effective manner. Recovery of energy from waste heat in the manufacturing environment. • Lean Language: ‘Kaikaku’ or eliminating waste • Intelligent Energy Use in Manufacturing Equipment: Development of best practices, methodologies and standards with regard to intelligent energy consumption by manufacturing. • Lean Language: Applying a ‘TIMWOOD’ view on waste to production lines • Compressed Air Systems: Focus on research, characterisation and modelling of compressed air end use (its applications). This is needed to develop efficiency models for users to understand their consumption efficiency and use. • Lean Language: ‘Jidoka’, ‘Autonomation’ or Condition Based Monitoring

  14. I2E2 Contact Details • Can I2E2 help you to lean out your energy consumption? • Our website is: www.i2e2.ie • Key contact for enquiries: Mark.Fitzpatrick@i2e2.ie

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