Smithfield Manufacturing is a manufacturing company located in Clarksville, TN that was founded in 1952. In recent years, the company implemented lean manufacturing practices and became green certified in 2012 in order to reduce waste and save on energy costs. Through projects like installing more efficient lighting, replacing an older air compressor with a variable speed model, and using thermal equalizers, the company was able to reduce its electricity costs by 10% and save $700 per month on air compressor costs. Smithfield's efforts to become more energy efficient also helped it receive recognition as the best small business green program in 2012.
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"Lean and Green" Energy Savings at Smithfield Manufacturing
1. “Lean and Green”
Energy Savings
at
Smithfield Manufacturing
Ron Smithfield, President
Smithfield Enterprises, Inc.
237 Kraft Street
Clarksville, TN
June 13, 2013
5. 60 Years in Clarksville
• 1952 Founded by Basil & Sue Smithfield
• 1988 Tennessee’s “Factory of the 90’s”
• 1989 started “Lean Manufacturing”
• 1999 Tornado destroyed half of plant
• 2000 BBB Torch Award for tornado recovery
• 2005, 2008 & 2011 ISO9001:2008 registered
• 2012 Green Certified
14. Environmental Policy
2. We will involve all of our team
members in being
environmentally responsible
while providing quality
components and services to our
customers.
15. SMI Goals within 12 months
(July 2011)
1. Reduce Electricity $ by 10%
2. Recycle more Metal Scrap $ by 20%
3. Reduce Oil &Coolant Disposal $ by 20%
4. Reduce Packaging $ by 10%
5. Reduce Transportation $ by 10%
16. Goal #1: Reduce Electricity $ by 10%
1. TVA audit – Replace 480 watt metal halide
lights with 277 watt T-5 electronic fixtures-
save 40%.
2. Set back thermostats for heating and cooling.
3. Turn off unused lights. Automatic lights for
safety. Motion detecting switches.
21. Lighting Project
• Pathway Lending, Nashville
• Application on line
• Terms: 5 years at 3% interest
• TVA study justified payback period < 5 years
• Installed by our maintence staff
26. Since Green Certification?
1. New high efficiency Air Compressor for
$700/mo savings
2. Replaced 20 yr old Heat Pump for office
3. Installed “Air Pears” to de-stratify heat
4. Replaced 2 old HVAC units with high
efficiency American Standard units
27. Compressed Air = Energy “Hog”
Before:
• 50 hp constant-running Air Compressor
• “Off-load” still used 60% power
After:
• 25 hp Variable Speed Air Compressor
• 40% of electricity (saving $700/month)
• Payback originally estimated at 4.5 years
• Actual payback about 3 years
38. “Air Pear” Thermal Equalizer
• Can project a column of air 50 ft.
Model 25 110 v. or 240 v.
39. “Air Pear” Thermal Equalizer (after)
• 1 – 2 degrees difference ceiling to floor
Our Results:
Team Members more comfortable & save heating cost
40. Approved for 5 years at 3% interest.
Savings greater than the monthly payment
Payback now estimated at 4 years.
41. • Tennessee companies only
• Energy savings evidence required
• Projects: lighting, HVAC, air compressors &
solar
• Payback of 5 years or less at low (2%) rates
• Loan applications at www.pathwaylending.org
42. 1. Saving $700/month with “Smart” Air Compressor
2. Saving $300/month with high efficiency lighting
3. Reduced coolant disposal by 40%
4. Reusing surplus pallets from local companies
5. Developed water saving “Meter Yoke Vise”
6. Installed “Air Pears” to de-stratify heat
7. New high efficiency HVAC units in plant
Smithfield Manufacturing
43. Energy efficiency in the office
1. Set-back thermostats
2. Replace T-12 with T-8 bulbs or T-5 fixtures
3. “Sleep mode” for computers during day
4. Turn off copiers, computers & power strips
5. Motion detectors to turn off lights
6. Double-sided printing
7. Reuse scrap paper on opposite side
8. Buy USA made products locally (if possible)
44. Lessons Learned
1. Have TVA or CDE conduct an Energy Audit
2. Apply for rebates before starting work
3. Get Team Members involved in setting Goals
4. Make Goals simple but achievable
5. Post Results very month
6. Compressed Air is expensive!
7. Use Pathway Lending to finance energy projects
8. Customers appreciate Green effort
46. “The worst form of WASTE is
saying you can’t improve.”
James Womack, Lean Consultant
Question?
47. The End
Contact:
Ron Smithfield, President
Smithfield Enterprises, Inc.
237 Kraft Street
Clarksville, TN 37040-3003
(cell) 931-624-5132, (Office) 931-552-4327,
(FAX) 931-648-4460
www.smithfieldmfg.com
Email: RonSmithfield@aol.com