RESEARCH BRIEF: Establishing audits for lean energy in the wood product industry

Bryan Stinnett,
MS Candidate, Virginia Tech

 

Lean Principles have traditionally been applied mainly in a manufacturing environment, but today it is being applied to most areas from the business office to health care facilities. The exception is in the area of energy, especially in regards to the wood products sector. It has been used in these areas mainly for the manufacturing, man power and supply chain systems.

Figure, 1. Audit steps (Energy Efficiency Planning and management Guide, 2002)
 

Our research will focus on three wood products companies in Virginia and with the assistance of an independent third party energy metering company. The metering company will take measurements before during and after lean recommendations are implemented. With the data from the metering company we will locate the key areas of energy consumption, and what the consumption rates are at peak and non-peak times. We have completed a walk through conditional energy survey and applied the survey to lean thinking at the three participating companies. By using lean thinking we will be able to eliminate waste (Muda). Lean thinking is a powerful antidote for waste (Muda). It provides a way to specify value, line up value creating actions in the best sequence, conduct these activities with out interruption when requested, and perform them more and more effectively. It also provides a way to make work more satisfying by providing immediate feed back. (Womack and Jones,: 2003) (Figure 1) shows the initial steps of the audit. It can be tempting to move quickly into the audit itself, especially for auditors who are technically oriented. However, understanding the ground rules in advance will help auditors to use their time more efficient, and will insure that the needs of the company commissioning the audit are met. (Energy Efficiency Planning and Management Guide, 2002

 
Figure 2. Wood kiln being constructed

Although the conditional survey preceded the main audit, it can also identify EMO’s (Energy Management Opportunities). The survey ratings helps identify and prioritize areas of the facility that should be examined more extensity. Some of the key EMO’s are, Lighting Systems, material handling systems, fans, heat pumps, compressed air systems dryers, kilns, and storage areas. (Figure 2) shows a new energy efficient kiln being constructed at a hardwood flooring company. (Figure 3) Is a materials storage area at the same hardwood flooring facility. These are just some examples of the areas we will be looking at. 

The audit mandate will make the audit’s goals and objectives clear and outline the key constraints that apply when the recommendations are implemented. The audits scope is the physical extent of the audit’s focus that should be specified, and the types of information and approaches that will identify the scope of the auditors work should be identified. (Energy Efficiency Planning and Management Guide, 2002)

With information from the metering and audits we will be able to define the scope then appropriate lean implementation for each company that will improve their efficiency, decrease cost and green house gases by eliminating waste and adding value

Figure 3. Warehouse

If you consider the energy crisis the world now faces it is necessary for more research in this area than ever before. When energy cost are low which they have been for long time people usually do not think about the wasted amounts of energy until the cost start to rise. 

References:

  • Energy Efficiency Planning and Management Guide, Natural Resources Canada, 2002. Web site; oee.nrcan.gc.ca/publications/infosource/pub/cipec/efficiency/index.cfm?attr=24
  • Womack, J. and Jones, D.2003, Lean Thinking: Banish Waste and Create Wealth in your Corporation.3rd ed. Free Press. New York, USA