ISO 50001 Energy Management System Case Study

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ISO 50001 Energy Management SystemCase StudyMéxicopressing challenges, such as the unsustainable demandfor energy resources. This commitment benefits ourclients in the form of more sustainable product optionsthat continue to offer the safety, performance, andreliability they expect.Ingersoll RandWorld-Class Energy EfficiencyThe Climate Commitment increases energy efficiencyand reduces greenhouse gas emissions in connectionwith our operations and products. It includes: A 50% reduction in the GG footprint of thecoolants in its products by 2020, and low-GWPalternatives throughout its portfolio by 2030. A 500 million investment in research anddevelopment related to products to finance thelong-term GG reduction.ISO 50001 certification audit by AWS, March 2018Organization Profile & Business CaseCase Study SnapshotIngersoll Rand is a world leader in the creation ofcomfortable, sustainable, and efficient environments forour clients, employees, and communities. We growthrough client-centered innovations that improve thequality of life and our environment, including those thatpromote sustainable commercial practices.We offer products and services that help clients reducetheir energy use and greenhouse gas (GG) emissions and,in so doing, help minimize the effects of climate change.At the same time, we work to reduce the energyfootprint of our own operations.“The implementation of ISO 50001 in ouroperations confirms our continuous energyimprovement and adds value to ourmanufacturing process.”IndustryManufacturingProduct/ServiceA/C equipment andHVAC unitsLocationMonterrey,LeonEnergy management systemISO 50001 & SEPEnergyperformanceimprovement period5EnergyPerformanceImprovement (%)28.8%over improvement periodTotal energy cost savings785 kover improvement period—Rigoberto Mena Alanis, energy leaderOur climate commitmentCost to implement EnMS74 kTotal Energy Savings25,399 GJover improvement periodIn 2014, Ingersoll Rand made an industry-leadingcommitment to help resolve some of the world’s mostTotal CO2-e emission reductionover improvement period13,140 TonCO2Nuevo

Global Energy Management System Implementation: Case StudyMéxico A 35% reduction in the greenhouse gas footprintof its own operations by 2020.Energy Performancemanagement.For Mexico and Ingersoll-Rand Manufactura S. de R.L.de C.V., the path to the implementation of energymanagement started on 3 February 2016 when thecompany formally joined the North American EnergyManagement Pilot Program (NAEMPP) of theCommission for Environmental Cooperation (CEC).Thisprogram, implemented in partnership with the ComisiónNacional para el Uso Eficiente de la Energía (CONUEE) ofMexico, the Department of Energy (DOE) of the UnitedStates and Natural Resources Canada, was created forprivate-sector industrial facilities in Canada, the UnitedStates, and Mexico with a focus on promoting theadoption of standard ISO 50001 & Superior EnergyPerformance (SEP) — systems occupying a position ofinternational leadership in energy management — andachieving certification under these standards.PlatinumLevel)inenergyThe SEP program administered by DOE consists of acertification scheme for auditing of energy savings infacilities holding ISO 50001 certification. Organizationscan use this program as a guide to the improvement oftheir energy performance, so that they achievecontinuous energy efficiency improvement in theirfacilities with attractive returns on the investment.With the adoption of this system, we have achieved an8.1% decrease in our average annual energyconsumption, in addition to US 152,000 in savings dueto the implementation of improvements and projectsderived from the various activities carried out by thesystem, including periodic measurement, review, andanalysis of energy consumption, energy audits, andenergy planning.Operational excellence has been maintained atIngersoll Rand with the use of the DMAIC methodology:The support of the CEC, assistance from CONUEE, andthe energy-related technical support, experience, andknowledge provided by the Georgia Institute ofTechnology (Georgia Tech) made it possible to concretizethe structure of the organization’s energy managementsystem. At Ingersoll-Rand Manufactura S. de R.L. de C.V., it isour mission to develop comfort and efficiency solutionswith sustainable, competitive, high-quality products,using the most advanced technology and operationalexcellence; to go beyond the needs of our clients and addvalue for our shareholders with the commitment andtalent of our people. Our vision is to be a global leader inoperational excellence and the best working team.Define the problemMeasure the impactsAnalyze the causesImplement the improvementsControl the solutionsIn this way, and working assertively, we successfullydetected areas of opportunity, including energyconsumption. In addition, our “A3” planning andproblem-solving tool enables us to stratify the steps tobe followed so as to address this area of potentialimprovement continuously over time. The steps aredivided into nine focus boxes in order to ensure effectiveprogress on the analysis of the actions and their results,so that we can effectively correct any deviations beforethey adversely affect the desired final outcome.Business BenefitsAt Ingersoll-Rand Manufactura S. de R.L. de C.V., wecan now say that we possess the tools and knowledgenecessary to administer energy resources, which are afundamental aspect of manufacturing operations. This isthe first and only Ingersoll Rand facility in the Americasto obtain both certifications (ISO 50001 and SuperiorThe structure of ISO standards based on the wellknown Deming cycle (Plan-Do-Check-Act) did not disruptthe industrial dynamic of operations in the organization;quite the contrary, it specifically and singularly helpedsolidify our management model since, by its very nature,it served to configure — step by step, phase by phase —2

Global Energy Management System Implementation: Case StudyMéxicothan 18 months, under the guidance, supervision, andcoaching of experts from the Georgia Tech energymanagement department, the full energy managementcycle was implemented under the Deming continuousimprovement structure set out in ISO 50001 andANSI/MSE 50021 (SEP). In tandem, energy audits of theplants were conducted to assist with the analysis of theenergy data as well as the identification of the USEn. Inour case, these are the three most important systems forour energy consumption and its variables (HDD, CDD, C,production units, air compressed). We identified themthanks to a tool provided under NAEMPP that serves tostatistically ascertain the relationship with theconsumption of each system. Simple energyperformance indicators, such as kwh/unit produced,were established.each and every clause of ISO 50001 using the DMAIC andA3 methodologies deployed by Ingersoll Rand across allits strategic business units. The comprehensive model isshown in the following figure:DMAICDMAIC-A3ISO 50KSEPIllustration 1. Energy management model of Ingersoll RandManufactureA review of historical consumption patterns shows astable cyclical trend, and a consideration of thenecessary specifications established for the baseline(2013 year) as per MSE 50021 helped us establish thoseof our EMS.PlanDuring the preparation and implementation of theEMS, the basis of the system was progressively put inplace with the support of senior management. Inaddition, a multidisciplinary team was formed withattributes and functions that enriched the developmentof the system.Companies that also participated in the NAEMPPincluded Cummins, Arcelor Mittal, and 3M, amongstothers. The workshops were held on the premises ofCONUEE in Mexico City; the training, understanding, andanalysis sessions focusing on ISO 50001 and ANSI/MSE50021 were held in 2016 and the first half of 2017. Theorganizational contexts for each particular sector werediscussed, and best energy-related manufacturingpractices were shared on the basis of the combinedexperience of the experts who participated actively inthese workshops. The final session consisted of trainingon the practical aspects of internal auditing and finalsystem documentation and was held at Ingersoll RandManufactura S. de R.L. de C.V. in the city of Monterrey,Nuevo Leon.Illustration 2 depicts the time period and each of thesteps followed for the implementation of the EMS.Illustration 2. EMS implementation timelineTo this end, an internal energy committee was formedat the Monterrey plant, bringing together the necessarytalents and profiles so that, over a period of slightly more3

Global Energy Management System Implementation: Case StudyMéxicoIllustration 3. Stages of the NAEMPPIllustration 5. EsquemaFrom February 27 to March 2, 2018, third-party (external)auditing was performed by Advanced Waste Management,Inc., a US-based auditing firm, resulting in arecommendation for certification of the EMS as per ISO50001:2011 and ANSI MSE 50021 Superior EnergyPerformance of the US Department of Energy.Illustration 4. Participants from Ingersoll Rand Manufacture andNAEMPP coaches at CONUEEDo, Check, ActThe internal energy committee of Ingersoll-RandManufactura S. de R.L. de C.V. is made up of RigobertoMena Alanís (senior management representative),Estefania Espinoza Treviño, Wendy Regalado Cruz, DavidTorres Medina, and Jesus Hernandez Caballero. Theseemployees are in charge of deploying the EMSimplementation strategy throughout the facility as perwhat was learned in the initial phases of the NAEMPPlearning network, with follow-up and technical supportas needed from Randy Green and Sandra Enciso (GeorgiaTech). Through progress report sessions held remotely asolid EMS structure has gradually been put in place andtaken its first steps in line with the organization’sstrategic objectives.4

Global Energy Management System Implementation: Case StudyMéxicoWe use GT EnPI Tool from GTech and EnergyPerformance Indicator Tool from U.S. Department ofenergy to demonstrate our energy performanceimprovement.Cost-benefit analysisThe investment in the EMS considered short-termaspects such as: Pilot program for the implementation of EMSin North America.Sub-measure infrastructure (BoomerangEnergy).Skill building.Third-party auditing (AWMS).“ISO 50001 has enabled us to assess energyperformance as a key component ofmanufacturing operations”—Rigoberto Mena Alanís, Maintenance ManagerThese helped to develop competencies which, incombination with the initiatives of the CONUEE learningnetworks, are now bolstering and solidifying energymanagement in our facilities. This represents a benefitnot only in economic terms but also in terms ofknowledge innovation, teamwork, and synergy alignedwith the values of Ingersoll Rand.Measures to maintain control of operations andprolong energy performance improvementsWe concluded that in order to achieve successfulcontrol of energy in an operational context, we must: Deploy a culture of strong energy performancein all manufacturing operations as acomponent of the operational excellencealready existing in the organization.Raise awareness to the importance ofoperational control among persons directlyresponsible for or involved in significant levelsof energy use (USEn).Intensive communication concerning the goals,objectives, and gains made with the EMS and theimportance of their participation in order to achievethese.Keys to successIllustration 6. Energy consumption behavior and energy saving 20132017.The energy improvement achieved up to 2018 wasconsolidated with the implementation of the ISO 50001EMS, yielding over 785,000 in savings, in addition tolower energy consumption and greenhouse gasemissions.As part of NAEMPP, We received statistical training toand tools needed to demonstrate energy performanceimprovement in compliance with the Superior EnergyPerformance Measurement and Verification Protocol(SEP M&V Protocol). We did some statistical regressions.5 Continually advocate for a system focus. Call for constant leadership and commitment. Involvement of EMS in activities under the control ofthe organization. Benefit all departments involved, all types andspheres of support for the manufacturing operation. Ensure that all members of the organizationunderstand the optimal energy performance that isbeing implemented.

Global Energy Management System Implementation: Case StudyMéxicoTransparency We participated in President s awards: Ingersoll Randrecognizes people efforts through President's Awards.And those are send to all organization. That way is torecognize outstanding employee contributions in keyareas of the company's vision. This is a prestigious honorwithin our organization. Also we communicated theachievement and the certificates through an email anddifferent meetings at Ingersoll-Rand Manufactura S. deR.L. de C.V. Monitoring of significant deviations and acting toresolve .2.2. Quotes and VisualsFollowing images demonstrate NAEMPP Cost:As well as on different websites like LinkedIn andYammer.Lessons Learned Understand and implement a standard based onperformance compliance.Build skills for demonstration of continuousimprovement through energy performanceindicators and auditing of energy goals andobjectives.Long-term strategic focus in order to ensuresufficient projects to achieve the energy goals ncompliance caused by failure to achieveanticipated energy t/analysis.Development and maintenance of an energy review.Establishment of baseline indicators and energyperformance.Setting and auditing of goals and objectives.Through the Energy Management Working Group (EMWG), government officials worldwide share best practices and leverage their collectiveknowledge and experience to create high-impact national programs that accelerate the use of energy management systems in industry andcommercial buildings. The EMWG was launched in 2010 by the Clean Energy Ministerial (CEM) and International Partnership for Energy EfficiencyCooperation (IPEEC).For more information, please visit www.cleanenergyministerial.org/energymanagement.6

ISO 50001 Energy Management System Case Study . México. 1 . Ingersoll Rand . World-Class Energy Efficiency . ISO 50001 certification audit by AWS, March 2018 Organization Profile & Business Case Ingersoll Rand is a world leader in the creation of comfortable, sustainable, and efficient

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