Deep Dive TrainingEnergy Efficiency in Industrial Processes

Deep Dive TrainingEnergy Efficiency in Industrial Processes

Foetz, Luxembourg

© Learning Factory 2016

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Production Line Utilities

Process Control Performance Management

A real factory to experience cost savings in industrial processes.

Energy Efficiency in Industrial Processes

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Since its foundation in 2013 the Learning Factory helps industrial and commercial enterprise clients to lower their operational cost and to improve their competitiveness.We achieve this goal with a sustained transfer of knowledge in the fields of energy efficiency and operational excellence.

Your Competitiveness is our mission.


Founding Members and Shareholders of the Learning Factory:

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The Learning Factory enables you to…

… lower operational cost … improve resource productivity … build employees capabilities


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…applied in our factory environment: Here our participants learn the practical

application of optimization tools.

… applied in your company: Our experienced experts accompany the

participants to their plant to help them applying obtained skills to achieve savings.

Our “Learning by Doing” approach…

Optimization of pump system – a practical exercise at the Learning Factory

Measurement-technical determination of saving potential at client site


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Process- & Performance-Management, Monitoring

and Dialog, EnMS

Three dimensions for your sustained success: These contents lead to cost savings in your plant.


TechnischesSystem Management

system

Fähigkeiten,Mindset, Verhalten

TechnicalSystem Management

system

Capabilities,Mindset, Behavior

e.g. cultivating change and creating a sense of responsibility for resource conservation

Acquisition of current state, process optimi-

zation, utility optimization

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Actual consumption

Operational losses: Associated with process control (e.g. ope-rators not following procedures) Reduction possible w/o capex.

Best Demonstra-ted Practice: Lowest document-ted energy use for the current system design (historical)

Design losses: Associated with process and equipment design that was previously developed

Theoretical limit: Minimum energy required theoretic-cally for a system to function (inde-pendent of design)

Our Methodology: We are focusing on the theoretical optimum and we distinguish two kinds of losses.

Identification of saving potential as difference between theoretical energy demand and measured consumption.


Assess current state Where am I today? Compare to historical

Where should I be?Determine theoretical limitHow far can I go?

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A holistic approach to optimizing utilitiesHydraulic circuits and pump systems

Industrial ovens and furnaces

Compressed air systems

Chillers and cooling towers

Fans and blowers

Steam and condensate systems


The Learning Factory has state of the art machinery and systems which allow a variable operating mode, thus enabling our participants to see the savings to occur in a real factory.

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Our tool box for process optimization.


Resource value stream mappingMap and quantify resources as they flow through each step in system

Loss bridge and theoretical limitIdentify minimum theoretical level of resource consumption

Line walk & energy measuresIdentify energy waste from waste, variability, and inflexibility

Load curve & cons. vs prod.Quantify perfor-mance losses on equipment/ process/ production

Process para-meter analysis1)

Quantify profit losses due to sub-optimal control of key parameters

Temperature mapping & pinch analysisQuantify losses due to sub-optimal reuse of heat

Network map & loss analysisMap and quantify losses in make-up distribution net-works (e.g., compressed air)Energy lifecycle analysisIdentify losses in the life cycle for each type of energy or resource

Machine system analysisPrioritize motors, pumps, & fans according to loss quantification due to inefficiencies

Cost curve

Quantify losses due to re-source demand-supply mismatch (e.g., cooling systems )

Utility matrix and energy cost

Initial prioritization of energy efficiency efforts

Consumption/ inventory analysisAnalyze variability of energy consumers

Shutdown analysisIdentify main lever to optimize stra-tegies for planned and unplanned downtimes

Actual versus designIdentify and categorize gap between planned and actual energy consumption

Reactive current analysisIdentify opportunities to reduce reactive current costs

Energy performance assessmentAssess the energy consumption practices within your company

1) Process parameter analysis tool can be used to a) reduce resource consumption, b) reduce unit price of resources, or c) optimize mix or improve price

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A learning journey through a real-life environment to build lasting capabilities.


Perfor-mance

time

Starting point:Current environment("waste walk")

End-state:Best practice("future state walk")

Dive into real-life company environments with real machines, real products, real services, real processes and real customers

Participate in interactive trainingstailored to the individual participants' needs

Experience step-by-step performance improve-ments

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The training fee per participant amounts to 5,300.00 EUR (plus VAT). This includes all needed material, documentation, provision of the production line incl.

operators, lunches and catering during all training days at the Learning Factory. Moreover we offer accompany of participants to their plant by our experts, in order to

support applying obtained skills to achieve energy savings for you. The daily rate for a senior expert amounts to 2,000.00 EUR (plus VAT).

Duration: 5 days (from Monday 10:00AM to Friday 4:30PM) Location: Learning Factory, Technoport 2D, Rue du Commerce, L-3895 Foetz, Luxembourg Next dates 2016: September 5 – 9, 2016 Language: English Terms of payment: Fees are payable within 15 days after receipt of invoice and before the

beginning of the training.

A training that pays off: Deep Dive Energy Efficiency in Industrial Processes


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Five days with a high proportion of practical training.


1. Day 2. Day 3. Day 4. Day 5. DayStart, lessons learned prev. day Start, lessons learned prev. day Start, lessons learned prev. day Start, lessons learned prev. day

Coffee breakCoffee break Coffee break

Coffee break

Identification of overconsumptionCoffee break

Coffee break Coffee break Coffee breakCoffee break

Wrap-up Wrap-up Wrap-upWrap-up

Shop floor Training room Catering

Closing feedback, End of training16:00 16:00

17:00 17:00

15:00 15:00Spotting and prioritizing energy improvement areas

Temperature map and pinch-analysis, integration of thermal energy and elimination of bottlenecks in process

Energy efficient electric motors and variable speed drives

Energy efficiency in buildings: Heating, ventilation and air conditioning (HVAC) and lighting

14:00Performance Monitoring Data acquisition and

measurement of energy consumptionIdentification of overconsumption

on a production line

13:00Resource value stream and process mapping

Optimization of active and passive cooling systems

Implementation and effectiveness of optimization measures on a real production line

Optimization of specific energy consumption (consumption vs. production profile)

Lunch breakLunch break

13:00 Definition of KPIs for resource efficiency

14:00

Resource value stream and process mapping

12:00Lunch break

Lunch break Lunch break

11:00 11:00Overview of Energy Efficiency

Analysis of specific energy consumption based on load curve

Blowers and fans12:00

10:00Energy efficient generation and drying of compressed airEnergetic optimization of industrial

ovens and furnacesEfficiency analysis of steam and condensate systems

Consumption optimisation of compressed air systems

Generation, distribution and utilization of steam, condensate recovery

09:00 09:00Holistic optimisation of hydraulic circuits and pump systems

10:00 Welcome, introduction, expectations, organisational

08:30 08:30Utility Matrix Identification of saving potential as

difference betw. theoretical limit and measured consumption

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Overview of energy efficiencyAcquisition of current state: Resource value stream and process mapping Identification of overconsumption: "Muda", inflexible

production facilities and process variability Spotting and prioritizing energy improvement areasProcess optimization: Utility Matrix Analysis of specific energy consumption based on load curve Optimization of specific energy consumption (consumption

vs. production profile) Temperature map and pinch-analysis, integration of thermal

energy and elimination of bottlenecks in process Identification of saving potential as difference between

theoretical demand and measured consumption Data acquisition and measurement of energy consumption

Overview of modules: Overview of energy efficiency, acquisition of current state and process optimization


Correlating of energy consumption vs. production profile

Deriving load curve

Identifying overconsumption due to inflexible production facilities

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Utility optimization: Energetic optimization of industrial ovens and furnaces Efficiency analysis of steam and condensate systems Optimization of generation, distribution and utilization of

steam as well as condensate recovery Optimization of active and passive cooling systems Consumption optimisation of compressed air systems Energy efficient generation and drying of compressed air Holistic optimisation of hydraulic circuits and pump systems Blowers and fans Energy efficient electric motors and variable speed drives Energy efficiency in buildings: Heating, ventilation, air

conditioning (HVAC) and lightingProcess and Performance Management: Definition of KPIs for resource efficiency Performance monitoring Implementation and effectiveness of optimization measures

on a real production line

Overview of modules: Utility optimization, process and performance management


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„Die gute Kombination aus technischem / praktischem Training und das Erlernen von Tools, um diese Kenntnisse auch organisatorisch im Betrieb umzusetzen, sind der Unterschied zu anderen Workshops / Tranings.“ Frank Michels, Dupont

“Energy costs are of major importance for the industry sustainability in Luxembourg. I believe the Learning Factory helps strengthen the capability needed for an effective energy management.” Alvaro Baudet, ArcelorMittal Belval

« Cette formation montre non seulement des concepts et des outils mais aussi une méthodologie mémorable de par la forme des exercices. »Patrick Bibollet, Schneider Electric

Satisfaction gets around. Customers from different sectors put their trust in us.


Cutting metalHealthcareGlass IT AdhesivesChemicalAdministration Mining Floorings

TobaccoPharma Rubber/tyres SteelMunicipalities

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Your contact to the Learning Factory


Christoph EmdeTrainer energy efficiencyPhone: +352 24 55 91 90Mobile: +352 691 674 [email protected] Factory S.A.Technoport 2DRue du CommerceL-3895 FoetzLuxembourg

Clémentine HyeulleMarketing & KommunikationPhone: +352 24 55 91 90Mobile: +352 691 670 [email protected] Factory S.A.Technoport 2DRue du CommerceL-3895 FoetzLuxembourg

We offer our trainings in English, French and German language.

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We offer our clients a comprehensive program for a sustained implementation of savings. Two participants of your company will carry out a project to achive energy savings in your plant. During the four months duration, the participants spend 4 x 3 days at the Learning Factory and will be accompanied by one of our experts, helping them applying obtained skills to achieve energy savings.The training fee for two participants amounts to 25,500.00 EUR (plus VAT)Included are 12 days of training at the Learning Factory and 4.5 days accompany of participants to their plant by one of our senior experts.Dates upon request.

Learn Do Apply (LDA)

Further offers by the Learning Factory: More than a training, less energy cost.


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Our trainings in Lean Six Sigma are based upon the complementary approaches of „Lean Thinking“ and the Six Sigma methodology. Participants learn to streamline processes, to eliminate non-value adding activities and to optimize the value creation.The methodology of value stream mapping and the DMAIC strategy (Define-Measure-Analyze-Improve-Control) are applied to processes within our production line. We utilize the statistic software Minitab® particularly for statistical design of experiments (DoE) within the Measure and the Analyze phase.Each participant prepares an individual project work at the Learning Factory, which will be assessed by a board of examiners. Participants are issued the Lean Six Sigma Green Belt or Lean Six Sigma Black Belt certification by the Learning Factory after successful completion of their project.

The training fee per participant amounts to 6,300.00 EUR (plus VAT)Duration: 6 days at the Learning FactoryMoreover we offer accompany of participants to their plant by our experts, in order to support applying obtained skills.Dates upon request.

Lean Six Sigma LSS Green Belt

Further offers by the Learning Factory: Operational excellence.


Details and dates upon request.LSS Black Belt

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We educate team leaders, particularly from production departments, following the concept of lean management with emphasis on enabling effective communication and proactive problem solving.Our methodology helps clients improving the team performance which in turn adds to their competitive advantage.The training fee per participant amounts to 5,600.00 EUR (plus VAT)Duration: 8 days at the Learning Factory (divided in 3 attendance phases)Dates upon request.

Team Leader

Further offers by the Learning Factory: Operational excellence.


Moreover we offer accompany of participants to their plant by our experts, in order to support applying obtained skills.

Deep Dive TrainingEnergy Efficiency in Industrial Processes

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