1. Energy Management In Manufacturing
Richard Russell, P.E.
Sr. Energy Engineer
Nissan North America

2. Nissan’s Commitments To
Improving Energy Performance
Cost Reduction
On Energy Spend
Nissan Green
Program 2016
ENERGY STAR®
Certification
Of Plants
DOE
Better Plants

3. Smyrna, TN Decherd, TN
Nissan Americas
Headquarters
Franklin, TN
Smyrna, TN
Canton, MS
2012
2011
2010
2009
2008
2007
2006
2012
2011
2010
2009
2008
2007
2006
2012
2011
2010
2009 Top 25% Energy Efficiency
Certifications

4. Use the Energy Program Assessment Matrix to evaluate your current practices.
http://www.energystar.gov/index.cfm?c=guidelines.assess_energy_management
Energy Management Systems
ENERGY STAR® Guidelines For Energy Management Matrix

5. Energy Management Systems ISO 50001

6. ISO 50001 Energy Management System Model
Energy Policy
Energy Planning
Implementation &
Operation
Checking
Monitoring
Measurement
& Analysis
Nonconformities,
Corrective &
Preventive Action
Internal Audit Of
The EnMS
Management
Review

7. Smyrna Vehicle Manufacturing Plant
Conditioned Space Area 5.5 MM Sqft
Production Capacity 550,000 Vehicles Per Year
Energy Sources Typical Annual Use
Electricity 220,000 MWH
Natural Gas 650,000 MCF
Coal 12,000 Tons

8. Stamping
Modern Vehicle Assembly Plants Are Complex
Assemblages Of Individual Plants

9. 0
10,000
20,000
30,000
40,000
50,000
60,000
70,000
80,000
90,000
100,000
-
100,000
200,000
300,000
400,000
500,000
600,000
Jan-05 Jan-06 Jan-07 Jan-08 Jan-09 Jan-10 Jan-11 Jan-12
Total Energy
Total Production
Smyrna Manufacturing Plant Monthly Energy Use & Production 2005 To Present
MMBTU/Month
Vehicles/Month
Base Line
Period
CY 2008
Baseline Year

10. Smyrna Manufacturing Plant Regression Model Study Of Energy Consumption
ProductionVolume(Total)
ProductMixCar
ProductMixTruck
HeatingDegreeDays
CoolingDegreeDays
AverageHumidity
AverageTemperature
Electricity ● ● X X 0.870 0.000 E = 2.93 x (Prod) +127.08 x (CDD) +93617
Electricity ● ● ● X X 0.880 0.00056 E = 2.134 (Car) + 3.786 (Truck) + 138.3 (CDD) + 98947
Gas ● ● X X 0.920 0.000 G=2.326 x (Prod) +84.732 x (HDD) - 27486
Gas ● ● ● X X 0.930 0.00005 G=1.68 x (Car) +3.111 x (Truck)+79.261 x (HDD) - 20852
Coal ● 0.323 ● 0.689 ● 0.642 ● X X 0.920 0.000 C=- 0.188 x (Car) - 0.254 x (Truck) +46.091 x (HDD)+19568
Coal ● X X 0.910 0.000 C=46.091 x (HDD)+19568
Not Evaluated X
P value <0.2 ● Applied
P value >0.2 ●
Models
Multiple
Regression
F-Test
Data
Energy
Source
Parameter Evaluated
Multiple
Regression
R square
Smyrna
Vehicle Plant
CY
2008
Model Testing - Analysis Of Relevant Variables

11. 7.2%
-5.0%
0.0%
5.0%
10.0%
15.0%
Sep-07 Mar-08 Sep-08 Mar-09 Sep-09 Mar-10 Sep-10 Mar-11 Sep-11 Mar-12
PerformanceTo CommitmentToAchiveSEP Certification 5%QualifingThreshold
SmyrnaMfg Plant In Scope ElectricityGas& Coal Consumption
Base Year
CY2008 EnPI =0
Silver
Gold
Platinum SEP Silver
=>5%
Performance Results

12. Annual Savings
MMBTU – By Source Bottom-Up Analysis
Electric Power 104,867 72,101
Natural Gas 52,078 51,139
Coal 93,174 5% Threshold 91,052
Total 250,119 173,091 < 214,292
Bottom-Up Sanity Check
Top 5 Projects Bottom-Up Analysis
1 Cascade Air & Dry Line Booth Controls Paint System 2
2 Boiler Flue Gas O2 Management & Insulation Projects
3 Compressed Air Management – Stamping Plant
4 Motor Speed Reduction – E-coat Circulation Pumps Paint System 1
5 Improved Start-up & Shutdown Procedures Paint System 1
Top 5 – 82%

13. 5
Things

14. New Value – Assigning the Paint System 2 E-Coat Oven
as our first Significant Energy Use, led to a better understanding
of its operation and the development of new relationships
with maintenance, engineering and production.
Value - Process Understanding
& Relationships
E-Coat Oven SEU
(Significant Energy Use)
1

15. Value -Finding Hidden Waste
0.9
0.95
1
1.05
1.1
-
2,000
4,000
6,000
8,000
10,000
Nov-09 May-10 Nov-10 May-11 Nov-11 May-12
Forecast Electricity (MWH)
Actual Electricity (MWH)
EnPI 12 Mo Moving Avg
Smyrna Boiler House
Predicted Vs. Actual Performance -
Electric Power Use Base Period Calendar Yr 2010MWH/Mo
EnPI
Based on control charts created using the EnPI tool, a re-
examination of management practice at our central chiller
plant identified cost savings that could be achieved without
investment!
This program implemented 11 months ago
has delivered a total of $67,000 savings.
2

16. 3 Validation Of Savings

17. 30% Reduction In Energy Intensity
75% Of Conditioned Paint
Booth Air To Be Recycled To Reduce Energy Use

18. 4 Support For Management Commitments
Are We Going To Meet Our Targets?
SEP processes and tools aid in forecasting,
documenting and verifying results. Third party
verification builds confidence in measured
improvements – on the shop floor, the executive suite
and the equities market.

19. 5 Design & Procurement
Did We Consider How This Equipment
Or New Process Will Impact Our
Energy Use, Consumption And
Efficiency?
Energy Engineers Are Now Approvers
On Shopping Baskets Over $50,000!

20. Value of Management Systems
• Method For Documenting & Tracking Cost
Savings
• Provides Third Party Verification & Rigorous
Measurement &Verification
• Public Recognition Of Savings
• Future Monetization Of Operational
Improvements