Energy audits get manufacturer WIRED

If you think you have high heating and electrical bills, consider this: Haynes International Inc. spends $9.5 million in natural gas and $5 million in electricity annually at its Kokomo, IN plant. The company is a leading developer, manufacturer and marketer of technologically advanced performance alloys, primarily for the aerospace and chemical processing industries.

07/15/2008


If you think you have high heating and electrical bills, consider this: Haynes International Inc. spends $9.5 million in natural gas and $5 million in electricity annually at its Kokomo, IN plant.

The company is a leading developer, manufacturer and marketer of technologically advanced performance alloys, primarily for the aerospace and chemical processing industries. Headquartered in Kokomo, Haynes has additional plants in North Carolina and Louisiana, with service centers throughout the U.S., Europe and China. With 1,200 employees worldwide, the company not only faces huge costs, but is also challenged with building and maintaining a skilled-trades workforce.

“We’re looking for employees who can problem solve and trouble shoot, not just follow instructions,” said Jean Neel, vice president for corporate affairs for Haynes. “Like all manufacturers today, we know that the kind of talent pool to keep our business growing strong requires a combination of safety awareness, environmental awareness, technical skills, problem solving and continuing education.”

Given the size of the company’s huge furnaces and related energy bills, Haynes was interested when it heard about a new program offered by the Indiana Manufacturing Extension Partnership center, through the Technical Assistance Program (TAP) at Purdue University. The program is part of a three-year pilot initiative in North Central Indiana, supported by a $15 million grant from the U.S. Department of Labor.

The Workforce Innovation in Regional Economic Development (WIRED) program is one of dozens across the country in which regional government, economic development and business leaders are working together to develop and implement transformational strategies focused on workforce improvements that will have long-lasting economic impact on the entire region.

Developing talent

For North Central Indiana, one of the key strategies is to “develop 21st Century talent,” explains Christy Bozic, manager of business innovation for TAP and the coordinator of the WIRED grant for the organization. Via the WIRED grant, the program has zeroed in on some of the key skills workers need today, by industry cluster, and is providing the training that will help these industries become globally competitive.

“Today’s workers and their employers need many new skills to succeed, compared to what was needed even just 10 years ago,” said Bozic. “Environmental training that will empower workers to identify and implement waste reduction and other environmental improvements is one of the most important.”

The program began with an energy assessment of the company, including onsite training and energy-stream mapping. TAP partnered with the Department of Energy for the assessment in which it identified ways to decrease utility bills, decrease production costs and curb emissions throughout the facility.

Targeting savings

One area the assessment pointed to for improvement was the plant’s gas-fired reheat furnaces. Through examining oxygen levels, gas consumption, quality demands, processes and leaks, the company realized within just a few months annual cost savings of half a million dollars in gas usage. “Given our enormous gas and electric bills, even just a small percentage in savings translates into big dollars,” said Neel.

For Haynes, the energy assessment was just the start of an ongoing sustainable program. The company gathered an internal team of employees to be trained, receive energy efficiency certificates and become energy stewards. This team is now routinely involved in reviews of the company’s production process, upgrades and capital improvements, with a goal to continually improve energy efficiency, conservation and emissions reductions throughout the plant.


Author Information
Ethan Rogers is the manager of energy efficiency services for the mfg@nist.gov .




Top Plant
The Top Plant program honors outstanding manufacturing facilities in North America.
Product of the Year
The Product of the Year program recognizes products newly released in the manufacturing industries.
System Integrator of the Year
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
June 2018
2018 Lubrication Guide, Motor and maintenance management, Control system migration
May 2018
Electrical standards, robots and Lean manufacturing, and how an aluminum packaging plant is helping community growth.
April 2018
2017 Product of the Year winners, retrofitting a press, IMTS and Hannover Messe preview, natural refrigerants, testing steam traps
August 2018
SCADA standardization, capital expenditures, data-driven drilling and execution
June 2018
Machine learning, produced water benefits, programming cavity pumps
April 2018
ROVs, rigs, and the real time; wellsite valve manifolds; AI on a chip; analytics use for pipelines
Spring 2018
Burners for heat-treating furnaces, CHP, dryers, gas humidification, and more
August 2018
Choosing an automation controller, Lean manufacturing
February 2018
Setting internal automation standards

Annual Salary Survey

After two years of economic concerns, manufacturing leaders once again have homed in on the single biggest issue facing their operations:

It's the workers—or more specifically, the lack of workers.

The 2017 Plant Engineering Salary Survey looks at not just what plant managers make, but what they think. As they look across their plants today, plant managers say they don’t have the operational depth to take on the new technologies and new challenges of global manufacturing.

Read more: 2017 Salary Survey

The Maintenance and Reliability Coach's blog
Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
One Voice for Manufacturing
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Maintenance and Reliability Professionals Blog
The Society for Maintenance and Reliability Professionals an organization devoted...
Machine Safety
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
Research Analyst Blog
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Marshall on Maintenance
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
Lachance on CMMS
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
Material Handling
This digital report explains how everything from conveyors and robots to automatic picking systems and digital orders have evolved to keep pace with the speed of change in the supply chain.
Electrical Safety Update
This digital report explains how plant engineers need to take greater care when it comes to electrical safety incidents on the plant floor.
IIoT: Machines, Equipment, & Asset Management
Articles in this digital report highlight technologies that enable Industrial Internet of Things, IIoT-related products and strategies.
Randy Steele
Maintenance Manager; California Oils Corp.
Matthew J. Woo, PE, RCDD, LEED AP BD+C
Associate, Electrical Engineering; Wood Harbinger
Randy Oliver
Control Systems Engineer; Robert Bosch Corp.
Data Centers: Impacts of Climate and Cooling Technology
This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
Safety First: Arc Flash 101
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
Critical Power: Hospital Electrical Systems
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
click me