AIE-Ceres 50001 Ready Webinar FINAL - Combined Heat ...

Get Ready for 50001 Ready: Next-Gen Industrial Energy

Management to Cut Costs & EmissionsSeptember 13, 2018

Agenda

• Welcome and introductions (5 minutes)• 50001 Ready Overview (10 minutes)• Presentations & Roundtable (15+15

minutes)• Audience Q&A (15 minutes)

Participants can submit questions through the GoToWebinar side panel.

Panelists


Dan Seligman Jay Wrobel Renee Smiljanic Rishabh Bahel

The Alliance for Industrial Efficiency is a growing coalition of business, labor, nonprofit organizations, and educational institutions that educate the public

and decision-makers and advocate for policies that increase U.S. manufacturing competitiveness through industrial energy efficiency, especially the use of Combined Heat and Power (CHP) and Waste Heat to Power (WHP)

Ceres is a sustainability nonprofit organization working with themost influential investors and companies to build leadership and

drive solutions throughout the economy. Through powerfulnetworks and advocacy, Ceres tackles the world’s biggest

sustainability challenges, including climate change, water scarcityand pollution, and human rights abuses. Our Investor Network on Climate

Risk now includes 161 institutional investors, collectively managing more than $25.2 trillion in assets.

Why 50001 Ready?• For industrials, energy-use and GHGs are the

biggest sustainability risks• Investors want companies to set, public EE goals

• Goals show companies have a strategy• Public goals show leadership has made a commitment• EE goals show company is serious about costs and

emissions• Yet just 43 percent of large industrials have public

EE goals• A robust EMS (50001) enables companies set and

achieve EE goals• 50001 Ready also allows companies to achieve

recognition from US DOE and EP100

Where do 160 US industrials standon EE & GHG targets?

•43% have public EE targets•79% have public GHG

targets •96% of companies with EE

targets also have GHG targets.

7U.S. DEPARTMENT OF ENERGY OFFICE OF ENERGY EFFICIENCY & RENEWABLE ENERGY

50001 Ready: Self-Guided Program to Set & Meet Energy Sustainability TargetsJay Wrobel, U.S. DOE

September 6, 2018


What is ISO 50001?

• ISO 50001 is a voluntary standard for establishing an energy management system– Known globally and transferable across multiple facilities/bases in every sector– Not a ‘project by project’ system but full organizational culture development– Think ISO 9000 or 14000 but focusing on energy and energy management

• 50001 Supports Efficiency– Establishes a continuous improvement practice across part or many facilities– DOE data shows savings persistent through the life of the 50001 practice– Follows proven plan-do-check-act cycle for continuous improvement– Identifies a list of energy opportunities to be evaluated over time– Staff turnover is eased by having written practice in place with roles and responsibilities– Top management turnover is managed as new manager inherits the practice as part of job

“Not only is our ISO 50001 important to the environment, but any opportunity for us to conserve directly affects the bottom line. The money we saved, $37 million, can be reinvested in the plant to create more jobs for the people here in Detroit.” —Jeff Allen, Detroit Diesel


50001: Increased Energy Performance

Multi-sites in 3M & Schneider-Electric showed a 2x improvement vs internal BAU

“ISO 50001 is a standard that drives results directly to the bottom line. ISO 50001 systematically drives down energy costs and improves competitiveness through the assignment of responsibilities and

raising the visibility of energy management within the organization.”—Andrew Hejnar, 3M


50001 Ready: DOE recognition for excellence

• 50001 Ready Program that provides…– Recognition Program from UD DOE for conformance to ISO 50001– Provides a tool to build your custom EnMS– Does not require certification from third parties– Comes with free resources (web, video, help desk) to streamline adoption– Applicable for all sectors of all sizes– Technical assistance available from FEMP, BTO and AMO– Means to coordinate and streamline your energy performance– Recognition is annual allowing for system maintenance and updating

Since May 2017, over 700 projects and 900 accounts in the 50001 Ready Navigator and 9 energy

utilities are partnering with DOE to offer 50001 Ready to customers!


How 50001 Ready Works

1. Implement ISO 50001 principles

2. Present energy performance

3. Self-attest to 50001 Ready

Sign-off by management of 50001 Readyimplementation and commitment DOE and others recognize

50001 Ready achievement

Complete 25 Tasks in US DOE’s 50001 Ready Navigator free, self-guided online tool

Submit energy performance data. May use EPA’s Portfolio Manager, DOE’s EnPI Lite or FEMP/OMB energy reporting data

energy.gov/50001Ready


50001 Ready Navigator - Overview• Free online ‘Turbo Tax-like’ tool, with step-by-step approach to ISO 50001

implementation• Guidance broken into straight forward sections, including:

– Getting It Done – what specifically needs to be accomplished– Task Overview – how does this task connect with ISO50001– Full Guidance – comprehensive guidance about the task– Transition Tips – from other ISO management systems or ENERGY STAR

• Form teams and assign tasks• Download guidance • Create multiple projects• Access over 100 related resources


50001 Ready Navigator Steps

Planning1. Scope and

Boundaries*

2. Energy Policy

3. Management Commitment

4. Energy Team*

5. Legal Requirements

Strongly prepared Partially prepared

• Having a Continuous Energy Improvement or Energy Mgmt. System means you are already at least HALF WAY DONE

Energy Review6. Data Collection

7. Data Analysis

8. Performance Indicators (EnPIs)*

9. Significant Energy Uses (SEUs)*

10. Relevant Variables

11. Baselines, Objectives and Targets*

12. Improvement Opportunities*

13. Improvement Projects

Continual Improvement

14. Monitoring*

15. Measurement*

16. Operational Controls*

17. Corrective Actions

18. Energy Consideration in Design

System Management

19. Documentation and Records

20. Communications

21. Training

22. Procurement*

23. Internal Audit

24. Calculate Energy Savings*

25. Management Review


Next Steps & Opportunities

1. Go to energy.gov/50001Ready for more information

2. Review the 50001 Ready Navigator (don’t have to register)

3. DOE offering free staff and informational resources to implement/pilot in one or more of your sites

4. DOE will coordinate with you on how 50001 Ready links to federal energy data reporting and energy audit requirementsContact [email protected] or [email protected]

for more info or to get started

mailto:[email protected]



Coming: 50001 Ready Workbook

• Under development is a Companion Workbook that:– Excel file to save on own hardrive (or shared drive)– Living spreadsheet that contains your 50001 energy management system– Includes built in Task worksheets and include the name/date of personnel– Makes completing Navigator tasks easier with own data and information– Use to on board new staff (management or staff)– Will contain sample completed forms to show end product example


Coming: Navigator Multisite

• Reduce time & effort of 50001 Ready across multiple facilities• Track 50001 Ready status of all sites• Platform for communicating across sites on 50001 Ready• Allows for ‘central office’ review or completion of tasks• Usable by utilities & customers; industrials & suppliers; etc.


Summary: 50001 Ready is…

Ø Getting recognized for best in class energy management

Ø A tool for onboarding new staff

Ø Institutionalizes energy management that can survive leadership change

Ø Builds off of current energy efforts

Ø Supports your efforts to meet mandates

Ø A way to develop and prioritize a list of continuous improvement opportunities

Ø Can be delivered by utilities, contractors, ESPCs

Ø Enhances resiliency by surviving staff disruptions

Ø Can break down internal stovepipes by creating collaboration

ArcelorMittal ClevelandISO 50001 Ready

Rishabh Bahel, CEM

ArcelorMittal has facilities, offices and joint venture partnerships in 14 states and the District of Columbia

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ArcelorMittal Cleveland (aerial)

Jennings Freeway

Steelyard CommonsI-71

I-490

I-77

#2 Steel Producing

C5 & C6 Iron Producing

HDGL & Finishing

Hot Strip Mill

#1 Steel Producing

Landfill

Covers more than 950 acres of land and seven million square feet of buildings

Sustainable Outcomes

21

22

27 Technical Best Practices(Comp. air, Steam, VFDs, Combustion, etc.)

Energy Benchmark Data BaseArcelorMittal is the largest steelmaker in the World

Digital LibraryWhite Papers, Catalogues, Guides

Quick Win ListA unified list of low/no cost example projectsdone in Company

Energy EventsPhysical Events (Global and Local)Web meetings to discuss projects and technologiesTreasure Hunts – Fishing Expedition

ArcelorMittal UniversityEnergy Training for Energy Champions

Energy Community WebpageAggregating all mentioned items

ArcelorMittal Energy ManagementBest Practices

22

ArcelorMittal toolbox for energy management

Good Communications Teamwork

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ArcelorMittal Energy PolicyOur Energy Policy has the key points:

Purpose: ArcelorMittal is committed to the efficient use and conservation of energy to reinforce its Leadership position and to assume its societal and environmental responsibilities for the benefit of all its stakeholders.Topics of our Policy.

• Efficiency• Technology• Social Responsibility• Partnering• Employees Engagement• Continuous Improvement• Supporting• Leadership

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Contest and Posters

• ArcelorMittal celebrates October as Energy Awareness Month.

• It encourages employees to be energy conscious and submit an energy savings idea.

• Each idea is evaluated on certain criteria.

• Winners win an attractive prize, this year we gave away Solargo Bagpacks.

Power of 1

Treasure Hunts

Copyright © ArcelorMittal

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• It is a process that focuses on identifying energy and water reductions opportunities in the workplace with no cost and low cost solutions with ROIs of less then a one year simple payback.

• It is a 2 to 3 day event at a specific area in a plant where a corporate cross-functional team works with local plant personnel to find energy and water reduction opportunities.

• It utilizes the diverse knowledge and experience of the team members (both hourly and salary) and it can be a training opportunity for employees,

• Heightens energy awareness

• The team analyzes and evaluates their findings and makes recommendations for implementation.

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Reasons for Implementing• In October, 2013, ArcelorMittal USA made a commitment to

DOE to achieve 10% Energy Reduction in 10 years. • ArcelorMittal Cleveland kicked off this challenge by hosting

DOE to conduct an In plant training and Process heating assessment.

• Projects are further identified and implemented to achieve this goal.

50001 Ready Overview

Key Actions in a 50001 Ready EnMS

q Set an Energy Policy

q Have management commitment

q Empower an energy team

q Identify where energy is used

q Create plans to improve energy use

q Management approval of plans

q Track progress and reassess energy

action plans

• The 50001 Ready program offers a no-cost way to receive recognition for establishing a

business practice around the management of energy. The program is not a certification

program, and does not require any third-party audits or verification.

• Participating in the 50001 Ready program provides your facility(ies) with the tools to implement

and maintain a structured, continual improvement-based EnMS.

Key Benefits of a 50001 Ready EnMS

q Manage risk associated with energy

performance

q Reduce energy-related costs

q Increase cost competitiveness

q Dedicate more resources to growing staff

and expanding production

q Demonstrate corporate leadership

50001 Ready Navigator

• The navigator has 25 tasks classified under 4 major segments: Planning, Energy Review, Continual Improvement & System Management.

• Each segment has easy description with available tools to assist.• 50001 Ready Help tool provides guidance for each task.

Reasons for Implementing

• Continuous improvement

• Recognizing the current Energy Management Program.

• Creating Energy Awareness within a steel company.

• To develop a base for full ISO

50001 recognition.

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Key Steps and Discovery

• Management approval.

• No external audit obligation.

• 25 task steps are easy to navigate.

• Covers all aspects of energy management

program.

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Outcomes• ArcelorMittal Cleveland – 1st

integrated steel mill to be ISO 50001 Ready recognized.

• ArcelorMittal Burns Harbor to follow

• Upper management satisfaction.

• To continue adopting other tools by DOE and achieve energy intensity goals.

31

Made in Comau

Corporate Presentation

Renee Smiljanic

Environmental and EnergyAIE / Ceres Webinar, September 13, 2018

Made in Comau 33

Index § Overview§ 50001 Ready Benefits § Implementation within Comau§ Navigation of the System and Process§ Results

Property of Comau - Duplication prohibited Made in Comau 34

Comau in the World

MI, USA

MEXICO

BRAZIL

ARGENTINA

SPAINFRANCE

UK GERMANY

CHINA

RUSSIA

ITALY

ROMANIA

INDIA

CA, USA

Updated at 01/01/2018

TURKEY

Made in Comau 35

COMAU Products Powertrain Automation Products Robotic Products

Standard Products Body Welding Products

Integrated Systems

Made in Comau 36

USA

Plant PropertyProperty Type Year

Owned -Rented -

Plant Area

Plant Layout

Area SqmFabrication 186Machining 3,530Painting 260Assembly 6,500Integration 18,115Certification 186Warehouse 1,570Offices 437Other 4,216

Total Covered 35,000

Plant Capacity BGT 2018

Production Capacity for BU 2018

# Picture Description Units/year

Product 1 Gripper 630

Product 2 Fixtures 2738

Product 3 Riser 300-400

Product 4 Tool Tray 20-30

Product 5 Geopallet 640

Product 6 Power roll beds 180

Product 7 BRIC 20-30

Product 8 941 pop up 20-30

Body

Ass

embl

y

Plant Workforce

Manufacturing & Engineering SystemsManufacturing Systems

(Type)Internal Manfacturing

Applications Engineering Systems

SAP (MRP) Mazatrol Catia GPS Fanuc AutocadPLM Seikos Smart Cam

SMX-farro Annilam UnigraphixCMM-PC Dmis 2014.1 Hiedenien Fides

Brady Smart CamRobcad

Novi Manufacturing Footprint

Manufacturing Headcount 2017 BGT 2018Direct 167 183

Indirect 44 36Total Internal HC 211 219

Contractor (yearly average) 112 132Total Headcount 323 351

Activity Competence Shift/Day Hours/Year Direct HC Hours/Year Contarctor Total H/yFabrication YES 2 42,000 3 7,744 1 49,744Machining YES 2 90,000 35 67,760 3 157,760

Mechanical Assembly YES 2 324,000 63 96,800 85 420,800Piping & Wiring YES 2 300,000 65 100,672 84 400,672

Certification YES 2 60,793 6 11,616 6 72,409Site - 144,000 - - 144,000

960,793 172 284,592 179 1,245,385Total Plant Capacity

Made in Comau

OHSAS 18001Implementation

ISO 50001Implementation



37

COMAU – Standards, Certifications and Awards

1997 2001 2011 2014

WCM Kick Off

2017201320122010 2015

WCM10

WCM21

WCM28

WCM29

WCM35

WCM41

2016

FCA - EHS Leadership

Awards 2015Health and

SafetyCategory3rd PlaceGlobal

WCM44

General MotorsCovetedSupplier

InnovationAward 2017

2018

DepartmentOf Energy

2017 Better Plants Program

And 50001 Ready

Facility Awards


Commitment to Sustainability

Comau, as part of FCA Group, is a member

of several major sustainability indexes,

including the prestigious Dow Jones

Sustainability Index (DJSI).

Made in Comau 39



Benefits

Internal External

• Good Environmental credentials and reputation with:

• Customers’• Suppliers• Investors• Organizations• Employees

• Support System:

• Knowledgeable Team• Monthly Meetings on Progress• Guidance Thru the Setup• Monthly Reporting Information• Continual Improvement Goals

Made in Comau 41



Implementation

• Department of Energy – Better Plants for Better Business Partnership

• Meeting with Comau Management

• Commitment to the Partnership• Support for the Partnership

• Monthly Meetings with the DOE on progress and planning

• Introduction to the 50001 Ready System

• Review and Investigate 50001 Ready System

• Implementation of the tool

Made in Comau 43



One Location

Innovation is a recurring theme that accompanies almost every activity within Comau and expresses itself with a combination of technology and style.

Innovation is a state of mind and a driver of excellence.

It’s also the area where we are considered significantly better than the competition.

Innovation is what challenges us to reach new heights in leading the culture of automation.


Step by Step Guidance

Innovation is a recurring theme that accompanies almost every activity within Comau and expresses itself with a combination of technology and style.

Innovation is a state of mind and a driver of excellence.

It’s also the area where we are considered significantly better than the competition.

Innovation is what challenges us to reach new heights in leading the culture of automation.


Worksheet Guidance

Made in Comau 47



Results

Implementation of the System with ease saving time and resources.

Confirmation that the process that was previously implemented meet the standard.

Recognition from the DOE for progress.

2011 to 2016

26.74%

Savings

2011 2012 2013 2014 2015 2016Actual Electrical (Source)(MMBTU) 155,116 161,700 148,253 146,722 139,336 112,319Actual Gas (MMBTU) 67,766 68,851 88,189 81,841 56,757 45,841TOTAL (MMBtu) 222,882 230,551 236,442 228,563 196,093 158,161 Adjustment Method Model Year Forecast Forecast Forecast Forecast ForecastModeled Electrical (Source)(MMBTU) 155,116 169,185 167,435 170,388 161,232 148,303Electrical (Source)(MMBTU) Annual Savings 0 7,485 19,182 23,666 21,896 35,984Modeled Gas (MMBTU) 71,014 65,168 76,991 83,266 74,899 67,588Gas (MMBTU) Annual Savings 3,248 -3,683 -11,198 1,425 18,142 21,746Total Modeled Energy Consumption (MMBtu) 226,130 234,352 244,426 253,654 236,131 215,891SEnPI Cumulative 1.000 0.984 0.967 0.901 0.830 0.733Cumulative Improvement (%) 0.00% 1.62% 3.27% 9.89% 16.96% 26.74%Annual Improvement (%) 0.00% 1.62% 1.64% 6.63% 7.06% 9.78%Annual Savings (MMBtu/year) 0 3,801 7,984 25,091 40,038 57,730Cumulative Savings (MMBtu) 0 3,801 11,785 36,877 76,915 134,645

Superior Energy Performance Results

The table below shows the unadjusted and adjusted energy consumption and intensity data. The models used to adjust the data for each energy source are shown below the plots and on the individual sheets for each energy source. Note that the tool selects the model that is appropriate for the SEP Program and has the highest adjusted R-squared value.

Via Rivalta, 30 - 10095 Grugliasco - Torino ITALY - www.comau.com

Made in Comau

Roundtable Discussion and Audience Q&A


Dan Seligman Jay Wrobel Renee Smiljanic Rishabh Bahel

Conclusions & Resources

• 50001 Ready • Energy.gov/50001Ready• [email protected] or [email protected]

• EP100• theclimategroup.org/project/ep100• [email protected] or [email protected]





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