Status: green
Project Start Date:

April 2010

DMAIC Phase: Define

Right First Time
Six Sigma Project
“Reduce consumption and demand of electric energy at
Vallejo Site”
Start Date: April 2010
Champion: Antonio Rodriguez
Black Belt: Daniel Santillanes
Sponsor: Ismael Toxqui
Team Members: Antonio Rodriguez, Omar Encinas, Moises Palma ,Daniel
Santillanes Luis Aguilar, Guillermina Mina, Jaime Briseno, Juan Luis Viquez

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Chillers units optimization at the Tlalpan Site

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Define

Measure

Analyze

Improve

Control

Project Charter
Project Name

Reduce consumption and demand of
electric energy

Business / Location

Vallejo Site, Mexico City.

Champion

José Antonio Rodríguez

Telephone Number

55 51813264

Black Belt

Daniel Santillanes

Telephone Number

Sponsor

Ismael Toxqui

Telephone Number

55 29557182

Process Owner

Moises Palma Cruz

Telephone Number

55 13403309

Start Date:

April, 2010

Target End Date:

Dicember,2010

Project Details
Project Description/

Business Case

Reduction of consumption and demand of the electrical energy at the
Vallejo site.
We could generate 10% of electrical energy savings with a potential cost
benefit of $160K USD per year.

Problem Statement

Currently we have many obsoletes equipments in lighting, motors,
compressors and bad practices in the use of electrical energy causing
high consumption and demand of electric energy mainly in the peak
schedule generating high operational cost.

Project Scope

Start: Includes the main charges above 20 HP and the illumination
systems of Pharmacy, Dryer I, Dryer II, Mixture, offices, warehouse and
laboratories.
Stop: All units related with the production process.
Excludes: All HVAC Units.

Define

Measure

Analyze

Improve

Control

Project Charter
Project Goals
Reduce the electrical
consumption at Vallejo
site
Reduce electric demand
at Vallejo site

Optimize the use of
electric energy in the
Site and reduce the
operational expenses.

Metric

Baseline

Goal

kWh

15,619,633 kWh/year

14,057,669 kWh/year
(-10%)

kW

2110 kW /month

2000 kW /month
(-5%)

USD

$1.37 MUSD/year

$1.23 MUSD/year
(- 10%)

Expected Business
Results

Reduce operational expenses in electric energy consumption and electric
demand in around $136,000 USD/year.

Expected Customer
Benefits

Operational conditions in the Manufacturing Process of Dryer I, Dryer II
,Mixtures, Pharmacy, ,Laboratories, & Warehouse areas will not be
affected.

Team members

Antonio Rodriguez, Moises Palma, Omar Encinas, Luis Aguilar, Ismael
Toxqui, Juan Luis Viquez.

Support Required

Daniel Santillanes.

Risks/Constraints

Current cooled water distribution system could limit the temperature set
point adjustments (Temperature and Water Flow balance).

Define Process Map MAIN SUBESTATION Measure Analyze Improve Control (Subestation Location) STOCKLIN SUBESTATION .

Define Measure Process Map Analyze Improve Control (Main Sub-station ) 740 TR-1500 kVA@ 440 VCA 30 TR 754161 MWh/month TR-1000 kVA@ 440 VCA Sub-1 UM-03-01 UM-03-02 TR-1000 kVA@ 220 VCA UM-03-04 30 TR UM-05-11 STERILE 1 HE (LVP) UM-05-09 STERILE 2 24 35 TR ONCO HE (WFI) UM-05-06 AHU-01 AHU-02 AHU-03 AHU-04 .

Define Measure Process Map Analyze Improve Control (Sub-station 2) UMA-301 62 MWh/month 70 TR UMA-500 UMA-601 Sub-2 HORMONALS UP-601 UMA-607 UMA-701 .

Define Suppliers Suppliers Measure Inputs Inputs Analyze Improve Process Electricity Local Electrical Supplier Local Water Supplier Maintenance team External services Spare parts suppliers SIPOC Outputs Outputs •Flow Specified temperature & RH conditions for: •Pressure •Hormonals Area •Temperature Environmental conditions Customers Customers Cooled water with specified values for : Water Chiller Operation •Sterile Area Operation Operational costs: •QO Lab Internal & External Maintenance •Energy •Packaging Area •Water •Non-Sterile Area Spare Parts Start Utilities supply: Utilities supply: Electricity Electricity Water Water Fresht Air Fresht Air Control Cooled Water Cooled Water (chiller units) (chiller units) •Labor •Maintenance Distribution Distribution Water system to Water system to HVAC HVAC units units Stop Water return Water return to chillers to chillers .

NMT 50% RH Reduce Electrical consumption No major investment Chillers performance Y for this project X1 X2 X3 X4 .Define Measure Analyze Improve Control Voice of Customer – Defining the CTQ for the Project Need Reduce in 20% the current Operational expenses due to chillers operation Drivers Y1 Y2 Manufacturing Areas environmental parameters Budget CTQ‘s (Critical to Quality) Temperature 18 to 22°C.

Define Measure Analyze Improve Control Chillers units optimization at the Tlalpan Site MEASURE CONTROL DEFINE Data IMPROVE Sampling MEASURE Pa tt ANALYZE Ca pa bi lit y ern s .

Electricity representing 72% of the budget .Define Measure Analyze Improve Control Chillers units optimization Why this project? Utilities budget in Tlalpan site is divided into 3 main subjects: Electricity. Fuels & Water.

Define Measure Analyze Improve Control Chillers units optimization Why this project? Priority for electrical saving opportunities shows better benefits .

Define Measure Analyze Improve Control Why this project? Arround 20% of Total Electrical consumption is originated by 5 chiller units (123 MWh/month). Consumption Sub-1: 480 MWh Sub-2: 200 MWh 12 (5 3 MW ch ille h rs) Total: 680 MWh 557 MWh (Others) .

Define Measure Analyze Improve Control Data Collection Plan Data Operational Definition and Procedures What Measure type/ Data type How Measured? Related Conditions to Record Sampling notes How/where recorded Energy consumption per chiller unit Continuous MWh/month To collect information using the general Power meters Last 2 years data Time series plot TR Compare design capacity vs used capacity Random sampling Pareto chart To collect and plot information Last year data Time series plot To collect and plot information Last year data Time series plot Chillers usage & available capacities Continuous PSI Pressure of water Continuous Rooms Temperature & Humidity Continuous °C & %RH .

Define Measure Analyze Improve Control Energy consumption measurement • The electrical network has power meters located in main branches. distribuited as shown in the next 4 slides. . • Power meters will be used to determine actual energy usage on each equipment.

Define Measure Analyze Improve Control Sub-station 1A Sterile Area .

Define Measure Analyze Improve Control Sub-station 1B Sterile Area .

Define Measure Analyze Improve Control Sub-station 1C: Oncology Area .

Define Measure Analyze Improve Control Sub-station 2: Hormonal Area .

Define Measure Analyze Improve Control Time Series Plot of Electrical Consumption 70 Variable Hormonals Oncology Sterile 1 Sterile 2 Lab 60 MWHr 50 40 30 20 10 0 Apr 05 J un 05 Aug 05 Oct 05 Dic 05 Feb 06 Apr 06 J un 06 Month .

00 $ 9.266.00 WCHU01 ONCOLOGY 100 TON 35% 35 32.680 $ 4.545.00 EAH-0301 LABORATORY / CNS 60 TON 50% 30 15.00 EAH-05-01 was considered in 2006 as a “bad actor” maintenance performance equipment for frequent and costly repairs.204.400 10.Define Measure Analyze Improve Control Technical Equipment Data: ID AREA NOMINA L CAPACIT Y EAH-0601 HORMONAL/ CYTOTEC 335 TON 21% 70 69.00 EAH-0501 STERILE 1 50 TON 60% 30 EAH-0502 STERILE 2 30 TON 80% 24 USAG E (%) USAG E (TON) USD/year (electricit y) USD/year (Maintenanc e) 10.600 $ 13.454.900.520 $ 22.190 $ 15. .

Define Measure Analyze Improve Control There are large unused capacity in the 5 chillers as follows: .

Define Measure Analyze Improve Control Temperature Trending in Manufacturing Areas Area: Hormonal Monitoring period: Two weeks .

Define Measure Analyze Improve Control Temperature Trending in Manufacturing Areas Area: Cytotec Monitoring Period: Two weeks .

Define Measure Analyze Improve Control Chillers units optimization at the Tlalpan Site ANALYZE DEFINE MEASURE IMPROVE ANALYZE Do E .

Use the Montecristo Chiller unit to provide cold water for all the site requirements (4 units shut off) Use the Montecristo Chiller and the Oncology unit. the Oncology and the Laboratory units (2 units shut off) . The unused available capacity from the Montecristo unit suggests the following possibilities: 1. we confirmed we have an opportunity to reduce the number of operating chillers at the site.Define Measure Analyze Improve Control Chillers units optimization • After the Define and Measure steps have been completed. 3. ( 3 units shut off) Use the Montecristo unit. 2.

Define Measure Analyze Improve Brain Storming Control .

Define Measure Analyze Improve Control .

Define Measure Analyze Improve Control .

Define Measure Analyze Improve Control .

Define Measure Analyze Improve Control Condiciones operativas de Chiller de Montecristo Vista y asesoría de proveedor del chiller de Montecristo (TRANE): En cuanto a operación y análisis de la correcta operación Sub utilización del equipo al 17-20% Mala práctica de operación del equipo a causa de número de arranques excesivo creando picos de demanda Identificación de ahorro Manipulación del seteo de temperatura Confirmación de potencial de ahorro Oportunidades: Necesidad de capacitación al arranque de equipos Necesidad de bitácora diaria de operación como monitoreo y tendencia Revisión de necesidades diarias del servicio de enfriamiento (cto 503) Necesidad de re-balanceo hidráulico por nueva conexión (EAH-03-01) Realizar FMEA para plantear riesgos .

Define Measure Analyze Improve Control Annual Maintenance Cost of Chillers of Sterile Area EAH-05-01 and EAH-05-02 EAH-05-01 Preventive Maintenance Corrective Maintenance $ 454 USD Total $ 15.000.545.00 USD One compressor One condenser Two fans One pump $ 25.00 USD $ 9.000.454.00 USD $ 15.00 USD Two compressors One condenser Three fans One pump EAH-05-02 $ 317.00 USD $ 9228.00 USD .

Define Measure Analyze Improve Control Work Orders and Hours of Corrective Maintenance of EAH-05-01 and EAH-05-02 ODT´s Hours 2004 2005 2006 EAH-05-01 4 2 6 310 EAH-05-02 2 5 3 216 .

Define Measure Analyze Improve Control Summary • The verified information in Define step confirms the availability of energy and maintenance savings by:  Optimize installed capacity usage and reduce at least two chiller units from operation. .

Define Measure Analyze Improve Control IMPROVE Solut io ns FMEA IMPROVE t Pilo t en m e n pl io Im tat - .

) – Add to savings all maintenance expenses (preventive.Define Measure Analyze Improve Control Generating. Evaluating and Selecting Solutions. we can rebalance electricity loads to explore possibility to eliminate the lease of a power emergency generator 300KW needed to back up the Oncology chiller unit. – By reducing at least two chiller units. • Brain storming: – Eliminate four chiller units and use only the Montecristo Chiller Unit. – Eliminate three chiller units and use only the Montecristo chiller units and the Oncology unit. corrective and calibration) related with the switch off units. . – Eliminate only the sterile area chillers (two units.

Quick Hit Project ONCOLOGY CHILLER LEASE GENERATOR 300 KW $ 4.000 USD/Month PUMP 1 PUMP 2 ONCOLOGY SUB-STATION HORMONAL GENERATOR HORMONAL SUB-STATION .

Define Measure Analyze Improve Control Solution Prioritization Matrix Eliminate Four Chillers and Use Just Chiller of Montecristo Eliminate Three Chillers and Use Chiller of Montecristo + Chiller of Oncology Eliminate Two Chiller and Use Chiller of Montecristo + Chiller of Oncology + Chiller of Laboratory Project Cost Execution Time Benefits High High (1 year) High Medium Medium (6 Months) Medium Low Low (3 Months) Medium According with the plan to cease the operation in the plant the best option is to eliminate only two chillers from the Sterile Area due to the execution time and the cost are low .

Define Measure Analyze Improve Control Work Schedule to Disable Piping of Chillers EAH-05-01 and EAH-05-02 of Sterile Area .

Define Measure 2” Analyze Improve Control 2” 3” 3” 3” 4” EAH-05-02: 30 TR WCHU-01: 100 TR EAH-03-01: 60 TR EAH-05-02: 335 TR EAH-05-01: 50 TR CURRENT COOLING LOOPS .

Define Measure 2” Analyze Improve Control 2” 3” 3” 3” Proposed chilled water system 4” EAH-05-02: 30 TR WCHU-01: 100 TR EAH-03-01: 60 TR EAH-05-02: 335 TR EAH-05-01: 50 TR .

Cost-Benefit Analysis: .

Chillers units optimization at the Tlalpan Site um en t i on r to at e Clo sur e IMPROVE Control c Do M Ev alu e rdiz nda Sta CONTROL .

Define Measure Analyze Improve Control Control Plan .

Saving of 12 MWh/month = 13.Define Measure Analyze Improve Control Improvement Results Arround 16% of Total Electrical consumption is originated by 3 chiller units (111 MWh/month).550 USD/year Consumption Sub-1: 374 MWh Sub-2: 294 MWh 1 (3 11 M Ch W ille h rs ) Total: 668 MWh 557 MWh (Others) .

Define Measure Analyze Improve Control Time Series Plot of Electrical Consumption Variable Hormonals Oncology Sterile 1 Sterile 2 Lab 70 60 MWHr 50 40 30 20 10 0 Month .

Define Measure Analyze Improve Control Time Series Plot of Electrical Consumption Antes Despues 70 60 Data 50 40 30 20 10 0 Date Panel variable: When Variable Hormonals Oncology Sterile 1 Sterile 2 Lab .

03 I ndividual Value 1 60 1 1 1 1 LCL=48.52 LCL=0 2 Dic 05 Mar 06 J un 06 Date Sep 06 Dic 06 Mar 07 J un 07 .Define Measure Analyze Improve Control I-MR Chart of Hormonals by When Before 80 After UCL=77.03 15 0 2 Mar 05 J un 05 Sep 05 __ MR=5.36 40 20 0 1 1 1 Mar 05 60 Moving Range 1 1 1 J un 05 1 1 1 1 1 Sep 05 1 Dic 05 Mar 06 J un 06 Date Before Sep 06 Dic 06 Mar 07 J un 07 After 1 45 30 UCL=18.71 _ X=63.

07 0 LCL=0 Mar 05 J un 05 Sep 05 Dic 05 Mar 06 J un 06 Date Sep 06 Dic 06 Mar 07 J un 07 .91 25 Mar 05 15 J un 05 Sep 05 Dic 05 Mar 06 J un 06 Date Before Sep 06 Dic 06 Mar 07 J un 07 After Moving Range UCL=13.Define Measure Analyze Improve Control I-MR Chart of Oncology by When Before After I ndividual Value UCL=47.29 10 5 __ MR=4.73 35 30 LCL=25.54 45 1 40 _ X=36.

Define Measure Analyze Improve Control I-MR Chart of Sterile 1 by When I ndividual Value 15 Before After 10 2 2 5 _ LCL=0 UCL=0 X=0 0 Mar 05 J un 05 Sep 05 Dic 05 Mar 06 J un 06 Date Before Sep 06 Dic 06 Mar 07 J un 07 After Moving Range 6.5 3.5 __ LCL=0 UCL=0 MR=0 0.0 4.0 1.0 Mar 05 J un 05 Sep 05 Dic 05 Mar 06 J un 06 Date Sep 06 Dic 06 Mar 07 J un 07 .

Define Measure Analyze Improve Control I-MR Chart of Sterile 2 by When Before After I ndividual Value 12 9 6 1 1 3 _ LCL=0 UCL=0 X=0 0 Mar 05 Moving Range 4 J un 05 Sep 05 Dic 05 Mar 06 J un 06 Date Before Sep 06 Dic 06 Mar 07 J un 07 After 3 2 1 __ LCL=0 UCL=0 MR=0 0 Mar 05 J un 05 Sep 05 Dic 05 Mar 06 J un 06 Date Sep 06 Dic 06 Mar 07 J un 07 .

35 1 Mar 05 J un 05 Sep 05 Dic 05 Mar 06 J un 06 Date Before Sep 06 Dic 06 Mar 07 J un 07 After Moving Range 6.75 2 10 LCL=9.0 LCL=0 Mar 05 J un 05 Sep 05 Dic 05 Mar 06 J un 06 Date Sep 06 Dic 06 Mar 07 J un 07 .14 12 _ X=11.9 0.0 4.Define Measure Analyze Improve Control I-MR Chart of Lab by When I ndividual Value Before After 18 16 14 UCL=14.0 UCL=2.5 1 3.941 1.5 __ MR=0.

Define Measure Analyze Improve Control Time Series Plot of Electrical Consumption 800 700 MW 600 500 Variable Sub-1 Sub-2 SUM 400 300 200 100 May 05 Aug 05 Nov 05 Feb 06 May 06 Aug 06 Nov 06 Feb 07 May 07 Date .