Live from WBF2008: Becoming Green--The Next Level of Manufacturing Optimization

Jim Parshall, from Eli Lilly and Company, presented on green MOM. What we're going to talk about: Current state of affairs Examples from industry What’s driving change and objectives for manufacturing Moving forward with WBF sus·tain·able – of, relating to, or being a method of harvesting or using a resource so that the resource is not depleted or permanently damaged [Merriam-Webster] sus·tain·abil·i·ty – a characteristic of a process or state that can be maintained at a certain level indefinitely [Wikipedia] Considerations? • Landfill Capacity • Global Warming • Peak Oil Focus for this Discussion • Improve manufacturing operations • Develop manufacturing processes to support innovative green product changes • Find alternative usages for by-products produced A Few of the Early Adopters or rather Activists: Ben and Jerry's, Patagonia, Body Works Mainstream Manufacturing Examples: Dow and DuPont have Chief Sustainability Officers, with sustainability links on home pages. P&G doubling concentration on liquid products. Unilever reconfiguring All and Suave. Coors, distilling waste beer into ethanol; Texas Instruments reusing silicon wafers for solar. General Mills burning oat hulls for energy and repackaging products. Otis is producing regenerating elevators. Eli Lilly – Green Past & Present • History of improving energy efficiency • Lighting and motor retrofits • HVAC off-hours temperature adjustments • High-efficiency chillers • Compressor air leak surveys and repairs • Fountain as cooling tower • But we could have done better • On-again/off-again recycling programs • Non-mandatory energy evaluations in past capital projects • Efforts underway today • Energy teams at sites • Cogeneration • Energy & Waste Reduction Fund (created in 2006) Driving Change • Policy – Government • Laws: Emissions, Fuel economy • Taxes: Fuel taxes, Carbon tax, Green tax credit • Global agreements: Kyoto Protocol Objectives for Manufacturing Reduce amount of raw material used Reduce energy consumed Reduce by-products (waste) produced and/or find alternative usages for by-products produced Adapt processes for innovative product changes Moving Forward – Role for WBF • Consider the standards WBF has helped to shape or has evangelized • What can WBF do to apply those same standards to help drive greener manufacturing? Example Opportunities for WBF • Evangelize • Publish sustainability application examples • Sustainability manufacturing theme for webcast or annual conference Application Examples • S88 • Recipe templates that include by-product accountability • Energy management equipment module reference designs • Regen / energy capture reference designs • S95 • Process and facility energy and waste management definitions • MES reconciliations for waste or by-product • Discrete operations • Principles and practices standard for operations efficiency behaviors and reporting • Facility management • BMS optimization standards