1. The John Deere Journey of Energy Efficiency
Beyond Treasure Hunts
The John Deere Journey of Energy Efficiency

2. Agenda
Background of Eco-Treasure Hunts Program Evolution Accomplishments

3. U.S. Industrial Energy Efficiency Survey (not necessarily Deere’s opinions)
> 90% reported an average payback of under 3 years is required
Energy Efficiency obstacles cited:
Low ROI vs. core business projects
Lack of Capital
Lack of Staff

4. Eco-Treasure Hunts at John Deere
Identified Need: Low-Cost and No-Cost Opportunities
2013: Bruce Bremer, Consultant
Dubuque, Iowa (May 2013)
Monterrey, Nuevo Leon, Mexico (October 2013)
Waterloo, Iowa (November 2013)
2014: Created John Deere Eco-Treasure Hunt Program
Continued global pilots
Adapted tool and events to John Deere
2015-Present: Active Program

5. Pilot Locations Mannheim (A&T) Dubuque (C&F) Saran (JDPS)
Waterloo (Tractor)
Harvester-EM (A&T)
Greenville (Turf)
Tianjin
(Ag, C&F, JDPS)
IJD-Monterrey (A&T)
Horizontina (A&T)
PILOTS for Process and Tool Creation, Training, Feedback….
(Changing, but still very large presence in North America.)
Diversity by:
A&T Region, and Environmental Regional Manager
Platform
Facility Size

6. Why perform an Eco-Treasure Hunt?
Focuses on low or no cost operational improvements Establishes a culture of continuous improvement and cross- functional collaboration Builds employee engagement regarding reduction of energy and water consumption and cost Aligns with 2018 Eco-Efficiency Goals
4 Key Parts
Cross functional teams
Wage Employees
Facilities Engineer
Maintenance Engineer
Leadership support
Non-production time
Implementation of the projects

7. 2018 Eco-Efficiency Goals

8. Opportunities for Energy & Water Efficiency
Small capital projects-Efficient lighting upgrades
Large capital projects-Building renovations
Procurement-Utility contract negotiations

9. Comments / Expected Benefits
Sample Agenda
Date: Day 1
Leader
Support
Time
Agenda Items
Comments / Expected Benefits
Team Performs Treasure Hunting During Non-Production*
Find opportunity/waste off production
Site Facilitator
7:00 AM
Meet at Main Entrance and Safety Training
ALL
7:15 AM
Meet in Private and Welcome Statements
7:20 AM
Personal Introductions and Meeting Schedule
7:30 AM
Eco-Treasure Hunt Training
Background and purpose
Support Facilitator
8:00 AM
Identify teams, Hand outs, Discuss Detail Sheets
8:30 AM
Split Into Team and Perform Production Treasure Hunting
Find opportunity ideas during operation
Team Leader
11:30 PM
LUNCH (Private Dining Room)
12:45 PM
Teams Summarize Questions & Opportunities, Group Review, Extra Treasure Hunting
Combine ideas into a list of potential opportunities, begin details sheets
5:00 PM
Perform Off-Production Treasure Hunting (Teams to be assigned)
Find opportunity ideas during off-production
ADJOURN
Date: Day 2
Meet in Private Dining Room
7:10 AM
Teams Summarize Off-Production Opportunities, Review, Performs Extra Treasure Hunting (if necessary),
Combine ideas into a list of potential opportunities, continue detail sheets, prepare top 3 findings per team
12:00 PM
Summarize all Findings
Generate list of potential opportunities, select items for further investigation and develop detail sheets, teams present top 3
1:00 AM
Modify and Provide to Facilitator all Completed Detail Sheets
Ensure Facilitator has access and calculations for all possible projects
1:30 PM
Closing Feedback Discussion
Comments and opportunities to improve
2:00 PM

10. Eco-Treasure Hunt Process
Identify Opportunities
Analyze Scope
Evaluate Impact
Implement Opportunities
Treasure hunt process is similar to the continuous improvement process-identify the opportunities, analyze the scope, evaluate the impact and implement the opportunities

11. Evaluate Impact: Eco-Treasure Hunt Tool
Details needed: Operating hours, power, meter readings, flow rates, temperatures

12. Results from an Eco-Treasure Hunts in FY2016
GCHPDC-Silvis
Energy Savings = 3% of spend
GHG Savings = 6% of total
Water Savings = 1% of spend

13. Results from all Eco-Treasure Hunts
Last Update:
Energy
Average Savings Identified 7.1%
Water
Average Savings Identified 1.0%
GHG Emissions
Average Savings Identified 6.8%
Average Payback = 0.67 years

14. Statistics
29 Completed
300+ Employees Trained
7 Countries
6 States
Countries: Brazil, Mexico, US, Germany, Canada, China, France,
States: Iowa, Tennessee, Illinois, Georgia, Kansas, North Carolina

15. Example: Pressure Washer
Opportunity
Washer was heating water at all times.
Improvement
Program existing timer to heat water only on production days/shifts.
Results
Savings: $2,900/Year
Implementation Cost: $0
Payback Period: Immediate

16. Example: Support Equipment
Opportunity
Welder cooling equipment running even when welder was off.
Improvement
Add relay tied to weld cooler power supply and weld machine so equipment is shut off when not in use.
Results
Savings: $934/Year
Implementation Cost: $100
Payback Period: 0.11 Years

17. Example: Cooling Water Reuse
Opportunity
Air compressor cooling water dump 30 gallons/minute into drain.
Improvement
Add feed to reuse for chillers
Results
Savings: 262,800 gallons/Year
Implementation Cost: $1,000
Payback Period: 0.5 Years

18. Example: Compressed Air Leak
Opportunity
10 individual air leaks, equivalent to 1cm in diameter
Improvement
Fix air leaks
Results
Savings: $22,515/Year
Implementation Cost: $1,000
Payback Period: 0.05 Years

19. Example: Compressed Air Leak
Opportunity
1 large air leak, took 5 seconds to fill a 10 liter bag
Improvement
Fix air leaks
Results
Savings: $1,108/Year
Implementation Cost: $25
Payback Period: 0.02 Years

20. Example: Paint Booth Lighting
Opportunity
Pain booth lights continually on
Improvement
Install timers on lighting to shutoff when booth not in use
Operators manually turn off
Results
Savings: $2,700/Year
Implementation Cost: $1,000
Payback Period: 0.45 Years

21. Did you know? Automation example: Ventilation/HVAC
Ventilation fans may be some of the largest motors in the factory
Compressed Air is an Expensive Utility
…easily 8 times the cost of electricity
Variable Frequency Drives (VFD):
Power savings are proportional to speed cubed*
Example: Running at 50% speed consumes 12.5% power*
Good applications include:
Most ventilation and process fans
Pumps with flow/pressure control
(use VFD instead of recirculation)
If installed, use it!
* This is theoretical pump or fan power; we adjust assumptions conservatively, but the savings are much larger than you would expect.

22. Lessons Learned Communicate, communicate, communicate
Do not tell facility that completing Eco-Treasure Hunt, except those on team
Potentially changes behavior of employees

23. Purpose of a Shutdown-Startup Procedure Focused Event
Reduce energy consumption and cost
Create a shutdown and startup procedure for departments or product lines
Create energy consumption dashboards for areas focused on large energy consumers
Identify low cost energy-saving projects
Calculate savings and financials
Identify and detail potential engineering projects
Reduce GHG emissions
Dalton or Jeff
Energy consumption is the enemy...the more energy you consume, the higher your utility bill

24. 24

25. Eco-Treasure Hunt Can be conducted with or without corporate support.
Similar to a Kaizen/Continuous Improvement event.
Can be conducted multiple times per year.
Calculator Tool provides rapid results for decisions and priorities*
Keys to Success:
Factory Manager, Operations support
Cross-functional team
Off-Production Treasure Hunt time
Implementation/Improvement Owner
* The Calculator Tool is a missing piece – may not be easy to duplicate at your company, but a simple spreadsheet might be good enough.