JUMP START REDUCTION PROJECT: BATTERY CHARGER, BLOCK HEATER AND PM’S

Problem: Allen Road experienced a high volume of jumpstarts on the CNG Vehicles and Diesel Trucks during the winter months.

Targets: Track cost on jump starts and frequency of battery replacement. Internal - Jumpstarts Number of Jumps Starts

Mechanic Labor Hours (est. 1/2 per jumpstart)

2015 - Maximo Vendor Spend Battery Spend

JAN 98 49.0 $ 4,420.00 $ 1,936.64

FEB 200 100.0 $ 6,765.00 $ 6,164.10

MAR 30 15.0 $ 2,430.00 $ 3,951.55

APR 37 18.5 $ 2,582.00 $ 514.62

MAY 21 10.5 $ 1,483.00 $ 774.86

Total 386 193.0 $ 17,680.00 $ 13,341.77

Root causes: Operators leaving auxiliary equipment and lighting on for extended periods draining the battery, CNG fuel regulator freezing up in extreme cold temperatures and maintenance. Targets: Increase productivity for Mechanics and Business Unit, Safety and reducing the number of jump starts.

Countermeasures • Pilot: Install battery charger on select CNG vehicles and Medium Duty Trucks. Identified vehicles by high volume of jump

starts and battery replacement prior to end of life using Maximo. • Consulted with Expert Auto to research best product. • Identified Progressive Dynamics to demo battery charger and verify that their product would met our specs. • Assigned a mechanic to work with Expert Auto on installation design • Tracking specific vehicles for pilot • Worked with HPP to identify home start vehicles that would benefit from this and would be willing to plug vehicles in at

their home. • Started installing block heaters for all CNG vehicles: Working with Ford dealership and internally for installation. • Enhanced PM Program, following Manufacture guidelines for spark plugs, filters and 5W 20 Synthetic blend oil

• Application of Circuit: When vehicle is plugged in the battery charger keeps the vehicles battery at optimal voltage, simultaneously charges battery and provides an additional 30 amps to support equipment left on i.e.: lights, inverter, etc., also, this circuit distributes power to the block heater and using a temperature switch activates below 40 degrees. The circuit is designed with only one outlet to plug in vehicle.

CNG totals Installed

Block heaters - Pilot $ 400.00

Vans 120 30

Medium Duty 20 4

Projected Cost Estimated $ 56,000.00

Charger Total

Battery Charger - Pilot $ 1,200.00 Installed

Vans 6 6

Medium Duty 12 12

Projected Cost Estimated $ 21,600.00

This is where the 120 volt input will be plugged in

Block heater union with the weather proof clam shell. This is mounted up high in the engine compartment on the passenger side.

Junction box which contains the adjustable thermostatically controlled switch. This is right next to the batteries

Chargers mounted on the rear cab wall will support up to 30 amps of output

CNG & DIESEL MEDIUM DUTY

Junction box located behind grill, containing adjustable thermostatically controlled switch. 120 Volt power input

Adjustable thermostatically controlled switch.

Battery charger mounted on partition. Charger will support up to 30 amps of output

Block heater union with the weather proof clam shell. This is mounted down low behind grill.

CNG VANS