Energy Management Case Studies - Nissan North America Inc.
1. Energy Management In Manufacturing
Richard Russell, P.E.
Sr. Energy Engineer
Nissan North America
2. Nissan’s Commitments To
Improving Energy Performance
Cost Reduction
On Energy Spend
Nissan Green
Program 2016
ENERGY STAR®
Certification
Of Plants
DOE
Better Plants
4. Use the Energy Program Assessment Matrix to evaluate your current practices.
http://www.energystar.gov/index.cfm?c=guidelines.assess_energy_management
Energy Management Systems
ENERGY STAR® Guidelines For Energy Management Matrix
6. ISO 50001 Energy Management System Model
Energy Policy
Energy Planning
Implementation &
Operation
Checking
Monitoring
Measurement
& Analysis
Nonconformities,
Corrective &
Preventive Action
Internal Audit Of
The EnMS
Management
Review
7. Smyrna Vehicle Manufacturing Plant
Conditioned Space Area 5.5 MM Sqft
Production Capacity 550,000 Vehicles Per Year
Energy Sources Typical Annual Use
Electricity 220,000 MWH
Natural Gas 650,000 MCF
Coal 12,000 Tons
10. Smyrna Manufacturing Plant Regression Model Study Of Energy Consumption
ProductionVolume(Total)
ProductMixCar
ProductMixTruck
HeatingDegreeDays
CoolingDegreeDays
AverageHumidity
AverageTemperature
Electricity ● ● X X 0.870 0.000 E = 2.93 x (Prod) +127.08 x (CDD) +93617
Electricity ● ● ● X X 0.880 0.00056 E = 2.134 (Car) + 3.786 (Truck) + 138.3 (CDD) + 98947
Gas ● ● X X 0.920 0.000 G=2.326 x (Prod) +84.732 x (HDD) - 27486
Gas ● ● ● X X 0.930 0.00005 G=1.68 x (Car) +3.111 x (Truck)+79.261 x (HDD) - 20852
Coal ● 0.323 ● 0.689 ● 0.642 ● X X 0.920 0.000 C=- 0.188 x (Car) - 0.254 x (Truck) +46.091 x (HDD)+19568
Coal ● X X 0.910 0.000 C=46.091 x (HDD)+19568
Not Evaluated X
P value <0.2 ● Applied
P value >0.2 ●
Models
Multiple
Regression
F-Test
Data
Energy
Source
Parameter Evaluated
Multiple
Regression
R square
Smyrna
Vehicle Plant
CY
2008
Model Testing - Analysis Of Relevant Variables
14. New Value – Assigning the Paint System 2 E-Coat Oven
as our first Significant Energy Use, led to a better understanding
of its operation and the development of new relationships
with maintenance, engineering and production.
Value - Process Understanding
& Relationships
E-Coat Oven SEU
(Significant Energy Use)
1
15. Value -Finding Hidden Waste
0.9
0.95
1
1.05
1.1
-
2,000
4,000
6,000
8,000
10,000
Nov-09 May-10 Nov-10 May-11 Nov-11 May-12
Forecast Electricity (MWH)
Actual Electricity (MWH)
EnPI 12 Mo Moving Avg
Smyrna Boiler House
Predicted Vs. Actual Performance -
Electric Power Use Base Period Calendar Yr 2010MWH/Mo
EnPI
Based on control charts created using the EnPI tool, a re-
examination of management practice at our central chiller
plant identified cost savings that could be achieved without
investment!
This program implemented 11 months ago
has delivered a total of $67,000 savings.
2
17. 30% Reduction In Energy Intensity
75% Of Conditioned Paint
Booth Air To Be Recycled To Reduce Energy Use
18. 4 Support For Management Commitments
Are We Going To Meet Our Targets?
SEP processes and tools aid in forecasting,
documenting and verifying results. Third party
verification builds confidence in measured
improvements – on the shop floor, the executive suite
and the equities market.
19. 5 Design & Procurement
Did We Consider How This Equipment
Or New Process Will Impact Our
Energy Use, Consumption And
Efficiency?
Energy Engineers Are Now Approvers
On Shopping Baskets Over $50,000!
20. Value of Management Systems
• Method For Documenting & Tracking Cost
Savings
• Provides Third Party Verification & Rigorous
Measurement &Verification
• Public Recognition Of Savings
• Future Monetization Of Operational
Improvements