Project Energy Reduction Estimating: How to use a Kaizen Calculator Tool to Standardize Savings Calculations

Kaizen is the term used by Japanese companies, most notably Toyota, to describe the change management process. Kaizen is a process of individual steps toward an overall goal. Change is a constant process, documenting each opportunity in a standardized format increases the kaizen implementation rate.

 

What is the bottom line impact of your energy decisions? How do they affect CO2, energy use and cost? This course is teaches the use of a standardized Kaizen Detail Sheet tool to calculate and confirm the energy savings impact of each decision you make. The tool provides management a clean single page description of the current condition and opportunity available and documentation the final product. Presenting the material to management in a standardized format will improve their understanding of each opportunity and improve your implementation rate.

 

Attendees will be shown how to set up a detail sheet for use at a single or multiple locations. Attendees will learn how to use raw cost data to determine the energy components of secondary energy sources such as compressed air and steam. Linked information will ensure that once data is entered for a given location it is used consistently to determine potential savings at that location.

 

Worksheet problems for simple electrical (Lighting and Motors), natural gas heating, compressed air and steam savings opportunities will be developed to explain Kaisen Detail Sheet use.

 

Complex problems involving multiple energy sources in a process will be explored to illustrate the overall impact of a kaizen project.

 

The development and use templates for similar processes will be explored and several standard templates will be provided to all attendees.

8:00am                                  
Introduction

 

8:30am                                   
Treasure Hunt Concept

 

9:00am                                   
Energy and Cost Savings Estimating

 

9:30am                                   
Electricity: How it is used & Elements of consumption

 

9:45am                                   
Lighting

 

10:30am                     
Fans/Pumps

 

12:00pm                     
Lunch

 

1:00pm                       
Natural Gas:  How it is used & Elements of consumption

 

1:15pm                       
Air Tempering: How it is used & Elements of consumption

 

3:00pm                       
Combinations

 

4:00pm                       
Practical Exam

 

5:00pm                       
End

 

ABOUT THE INSTRUCTOR He has been a key developer of the Toyota Energy Treasure Hunt and associated tools. A Treasure Hunt combines the knowledge and talents of all those involved with the manufacturing process: energy engineers, production engineers, and production and maintenance team members in identifying and implementing energy improvements in all of Toyota’s North American Facilities.