Value of Unique ARs in Improving Implementation Rate

Mike HeidariMechanical Engineering Graduate Student

Bradley University

© M.Heidari, Feb.2005

Outline

Discussion of the Value of Unique ARs.

Introducing a Road Map for developing unique ARs.

Categories of ARs:Category of Energy Assessment

Recommendations.

Category of Productivity & Waste Assessment Recommendations.

Category of Unique ARs.

Category 1: Energy Assessment Recommendations

EARs

Compressors

Lighting

Boilers

Motors

Repairs

Heaters

Ovens

Cooling

Waste Heat1. BUIAC, Implementation Rate Analysis and Corrective Actions Reports (Oct. 2004), Page3.1. BUIAC, Implementation Rate Analysis and Corrective Actions Reports (Oct. 2004), Page3.

Category 2: Waste & Productivity ARs

WARs &

PARs

Automation

Recycling

Bills

Selling

Leasing

Demand Control

Suppliers

Resource Waste

1. BUIAC, Implementation Rate Analysis and Corrective Actions Reports (Oct. 2004), Page3.1. BUIAC, Implementation Rate Analysis and Corrective Actions Reports (Oct. 2004), Page3.

What are Unique ARs?What are Unique ARs?

Specific Client or Specific SituationSpecific Client or Specific Situation

Unique ARs include EAR, PAR, WARUnique ARs include EAR, PAR, WAR

Category 3: Unique ARs

Replace Synthetic Oil-Based Coolant with Vegetable Oil-Based Coolant

(WAR)

Examples of UNIQUE ARs

Examples of UNIQUE ARs:Examples of UNIQUE ARs:

Using CRYOGENIC COOLING System to Using CRYOGENIC COOLING System to increase tool life timeincrease tool life time

© Air Products and Chemicals, Inc.© Air Products and Chemicals, Inc.

Examples of UNIQUE ARs:Examples of UNIQUE ARs:

Replace Mineral Spirit Washer with Automatic Soap Replace Mineral Spirit Washer with Automatic Soap and Water Cleaning Systemand Water Cleaning System

Unifies cleaning processUnifies cleaning process

Saves timeSaves time

Eliminates the cleaning solventsEliminates the cleaning solvents

Eliminates loss through spilling and leakingEliminates loss through spilling and leaking

The Mag 30 Automatic Cleaning System is in use on the shop floor of Alger The Mag 30 Automatic Cleaning System is in use on the shop floor of Alger Manufacturing Company.Manufacturing Company.

What is Implementation Rate?What is Implementation Rate?

The Percentage of the Actual Amount of Energy or The Percentage of the Actual Amount of Energy or Money a Client Saves Relative to the Amount Money a Client Saves Relative to the Amount Recommended.Recommended.(1)(1)

1. BUIAC, Implementation Rate Analysis and Corrective Actions Reports1. BUIAC, Implementation Rate Analysis and Corrective Actions Reports (Oct.(Oct. 2004), Page1.2004), Page1.

Why is the Implementation Rate Important?

IR is the measure of IAC performance.

IR impacts the way we work, learn, and live.

IR is the measure of the efficiency of ideas, not just a tool for IAC managerial level.

IR is the key to understanding psychological technological-economic trends of the industry towards the IAC program.

© M.Heidari, Feb.2005

Energy Implementation Rate% (MMBtu / MMBtu)

TES = Total Energy Saved in each AR category

TESR = Total Energy Saving Recommended in each AR category

EIR shows what percentage of energy saving recommended in each category is implemented.

© M.Heidari, Feb.2005

S1

0.0

20.0

40.0

60.0

80.0

Energy Implementation Rate% (MMBtu/MMBtu)

© M.Heidari, Feb.2005

Dollar Implementation Rate% ($/$)

TDS = Total Dollars Saved in each AR category

TDSR = Total Dollar Savings Recommended in each AR category

DIR is shows what percentage of dollar savings recommended in each category are implemented.

© M.Heidari, Feb.2005

S1

0.0

20.0

40.0

60.0

80.0

100.0

Dollar Implementation Rate% ($/$)

© M.Heidari, Feb.2005

Potential Dollar Saving per AR ($/AR) Potential Dollar Saving per AR ($/AR)

TDS = Total Dollars Saved in each AR category

TNI = Total Number of Implemented ARs in each category

PDS is the average dollar amount saved for each implemented AR in each category.

© M.Heidari, Feb.2005

Potential Dollar Saving per AR ($/AR)

0

20000

40000

60000

80000

100000

120000

Com

pres

sors

Ligh

ting

Boile

rsM

otor

sRe

pair

Aut

omat

eRe

cycl

eH

eate

rsW

aste

Hea

tO

vens

Bills

Cool

ing

Selli

ngW

ater

Reso

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Pain

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© M.Heidari, Feb.2005

Potential Energy Saving per AR Potential Energy Saving per AR (MMBtu/AR)(MMBtu/AR)

TES = Total Energy Saved in each AR category

TNI = Total Number of Implemented ARs in each category

PES is the average energy saved for each implemented AR in each category.

© M.Heidari, Feb.2005

Potential Energy Saving per AR (MMBtu/AR)

0

500

1000

1500

2000

2500

3000

3500

4000

Com

pres

sors

Ligh

ting

Boile

rsM

otor

sRe

pair

Aut

omat

eRe

cycl

eH

eate

rsW

aste

Hea

tO

vens

Bills

Cool

ing

Selli

ngW

ater

Reso

urce

Pain

tO

ff-Pe

akSu

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rsLe

asin

gU

niqu

e

© M.Heidari, Feb.2005

Implementation Coefficient (%IC)

TNIA = Total Number of Implemented AR

TNRA = Total Number of Recommended AR

IC shows what percentage of recommended ARs in each category are implemented.

© M.Heidari, Feb.2005

Implementation Coefficient (IC%) of each AR Category

0.010.020.030.040.050.060.070.080.090.0

Com

pres

sors

Ligh

ting

Boi

lers

Mot

ors

Rep

air

Aut

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Rec

ycle

Hea

ters

Was

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Coo

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Sel

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© M.Heidari, Feb.2005

Seven P!Road Map for developing Unique ARs with high

implementation potential.

“Unique ARs need unique approaches.”

© M.Heidari, Feb.2005

7Ps:

Pre-Audit Preparation Partnership Pre & Post-CommunicationProvide InformationPresentationProfessionalismPersistence

© M.Heidari, Feb.2005

Pre-Audit Preparation

For Unique ARs, pre-audit Preparation is Vital.

Do your research!

Familiarize yourself with the company’s

processes and equipment.

Organize your discoveries and thoughts

Tools for Pre-Audit Preparation

Pre-Audit Form

Online Research:Company’s Website

Audit Related TopicsIAC websiteSimilar Companies’ Websites

Specialized Journals, Books, Ref. Materials

Ask Experts

Partnership

Consult with your Team Members

Share Information

Brainstorm Unique AR ideas

Cooperation is Essential

Share the Workload

Pre & Post-Audit CommunicationBefore Audit:

Ask Questions to Clarify your Goals Identify the Major Decision Makers

During Audit:

Ask Specific Questions Carefully Listen to Workers and Management Understand Client’s Needs and Preferences Discuss Your Ideas and Get Feedback Identify the Major Decision Makers

Let’s Communicate!

Pre & Post-Audit Communication

After Audit:

Share your FindingsExplore & Share New IdeasUse Language the Client UnderstandsBe ClearBe SpecificRequest Manufacturer FeedbackFollow Through

Provide Information

Be ready and willing to respond to client’s questions.

Address client’s concerns.

Have accurate and well organized information ready to distribute to client.

Examples of what to Provide:

Cost-benefit analysisRelevant case studiesSchematics to help client understanding Implementation Roadmap

Describe the steps that need to be taken Milestones (visioning what progress will look

like along the way)

Let’s Implement!

Presentation

“Unique ARs require Unique Language”

Give Specific Directions

Organize Data Information Clearly

Make your report as Client-Friendly as possible to improve Implementation

Professionalism

Conduct yourself professionallyBe responsive to and respectful of clients needs.

Speak professionally

Be certain of all of the information that you offer.

Act professionallyKeep your word. Work efficiently. Meet

deadlines.

PersistenceUnique ARs require diligence

Don’t give up a good idea easily!

Even when your Unique AR idea has won internal (IAC) and external (client) acceptance, you still need this very important factor to complete the job.

You must be persistent to gain momentum!

Conclusion:

Unique ARs are important because of their psychological-technological-economic impacts.

Generate client interest Utilize advanced technology Have high money & energy saving potential

Questions?

Special Thanks to:

Dr. Paul MehtaBUIAC Director

Dr. David ZietlowBUIAC Assistant Director

Ms. Ellie NajafiBusiness Specialist BUIAC

Student Engineer Colleagues in BUIAC

Some Unique ARs 4U!

EAR1: When you are angry, you lose steam.

So, don’t get angry!

EAR2: When you are sad, you lose air.

So, don’t be sad!

© M.Heidari, Feb.2005

Thank you