Coming up on the Better Buildings Challenge SWAP.
Look at all these robots. There's so much, uh, compressed air requirements
for all of those moving parts. CARLOS: Yes, just to keep it there.
That stop sign is getting a ton of wind.
Air vents up there, you got a bunch of air vents up there.
L'Oréal
General Motors
Hosted by Maria Vargas from the U.S. Department of Energy.
Two energy teams, swapped.
We are so excited to be here at General Motors.
Since we're on the plant floor, GM, we're wearing our safety glasses.
We're looking forward to seeing your plant.
Julio Garcia, you're the plant manager here, thank you so much for having us.
Maria we're very excited to have you here, let's see
what the L'Oréal team can find.
Making cars and mascara is different, but at the end of the day it's manufacturing
and we have similar processes.
I think we can find some good opportunities for them but also take some best practices for us
We have our own mini SWAP within a SWAP. Danielle wasn't able to join us,
but Lauren Page is here and she was there with us behind the scenes in Arkansas,
but we're thrilled your here today.
LAUREN: Thanks, it's great to be here on behalf of the L'Oréal team
Well L'Oréal team, today is your day to see what you can find.
So Julio, if it's ok with you we'd like to go see your plant.
JULIO: Ok, let's go. MARIA: Let's go!
Energy is, uh, one of our 9 sustainability goals.
Energy instensity reduction. And we're on path to do that, which is really exciting.
Detroit Hamtramck is about a 4.1 million sq ft assembly plant.
We assemble 4 vehicles; the Buick Lacrosse, the Chevrolet Impala,
and the Chevrolet Volt, which is an extended-range vehicle
As well as the Cadillac CT6 which also can have a super cruise option.
Welcome to our body shop. This is the first step in the vehicle manufacturing process.
This is where the stamped metal that makes up the vehicle body comes together.
We've got 1100 robots and just over a million sq ft of floor space.
Alright, thank you. We're gonna go take a look.
It definitely is not running right now.
That could be the first opportunity, is I wonder if these are powered up right now when they're not in operation.
Yes. Cause if you just look at all these robots, there's so much, uh, compressed air
requirement for all those.
I wonder if they turn off when the shift is over or over the weekend.
Yeah, we can find out
Compressed air is a big use of energy at our factories too, right?
Yep, sure is.
We have movement.
So one of the things would be while it's not in use right here, it's still powered.
So if they had automatic air dump valves, uh, they could power that down.
and that would lessen their energy requirement.
Maybe another opportunity, and we can ask them is how do they do technical walks,
to identify air leaks.
ERIC: Hi! WOMAN: Hi!
I'm Eric how are you? WOMAN: I'm good.
ERIC: Whatcha doin' over here?
WOMAN: I am building the windshield for the Buick Lacrosse.
ERIC: Oh, very cool.
So is that suction that's being used to hold the glass?
WOMAN: That is suction being used. Suction from the waste to hold the glass up.
So when the shift ends, you know, does the air, does the machine stay on?
Does the air stay in or does it totally shut down?
It shuts down.
OFF CAMERA: It shuts down completely?
For energy purposes
As the operator of this line is there any sort of energy efficiency measures that you're able to take?
Yeah, absolutely. With everything that's going on up in here we are now trying to save energy.
Turning off the monitors, we're turning off the lights every break.
Is there stuff that you learn at work that you can take home with you to save energy?
Just mainly turning off the lights and the monitors.
That's like the biggest thing.
Alright guys, so you see the production line has stopped here.
So, in about another minute we're gonna see the lights turn off as well.
So the whole facility, they turn off?
So the overhead lights you'll still see, it'll be enough for people to walk safely around
but we turn the line lights off automatically.
You have any maintenance activity during the shutdown?
Sometimes, yes. So there you see the lights.
Yeah, so if you guys wanna go take a look, go ahead.
Yes, thank you
And this is the time where you can really hear any air leaks, or...
Yeah, I hear some right now.
That stop sign is getting a ton of wind.
Let's go
Look at that thing move.
It's moving, it's being pushed by something.
Air vents up there, you gotta buncha air vents in there.
There's a different range of temperatures in each of these –
Oh wow, look at that; look at how bright that is compared to the other one.
So it looks like this is where the cars come off the line and I've been noticing that there's a ton of
fluorescent lighting around.
Maybe they don't need all this light on or if they need it,
probably, they can just find a better way just to turn it on when they need it
Another thing I've seen is that car – if they have to open the door to let the cars off the line
and outside, then it has been good to see that if,
when the car approaches, it opens and then closes pretty quickly afterwards
They don't – like, let that much of the air in and out.
You are right.
I'm wondering if they can have a trap.
You know as in our plants, in order to maintain, you know, the stability of the air
we have two air curtains or two double doors, so you move the car into a door and then close this one
so you maintain air in there.
So, I wanted to introduct you to Phil Malara. He's from Hamtramck Energy and he runs our powerhouse here.
So, if you could give us kind of a high-level overview of the powerhouse operations,
and then we're going to let them go out and look for some opportunities.
Excellent, uh back here in the powerhouse we take all the utilities in.
Water, electric, steam, and process it for building the cars.
So, over here, we have our Energy Management System.
I can see all the compressed air and what departments are using what.
I can see steam, electric, temperature, natural gas, and water usage.
I learned a lot from their energy-management system and that brings technical
wins that we can bring back to our factory and make some improvements.
Let's let them go. Let's go find some opportunities.
ALL: Thank you
Safety glasses and earplugs.
Take a look at this too –
A good practice on their valves is, they should have some match-marking,
to show what the normal range is.
So, this may be controlled by their energy-management system.
but if it's a manual operation, it's really hard to know what normal is.
What I'd recommend is that they have some match-marking for all their manual gauges over here.
See if you can feel this heat.
Oh, I can feel some air coming out. Should we use the detector and see?
You can see yeah, we're up at eight or seven – that's great.
Yeah that's interesting.
Yeah, nothing over there.
You can find a lot of leaks with that tool.
Very cool.
You know, the other thing to notice right here is their lights.
So, these are all retrofitted LED lights, you can tell, and it looks like they have occupancy sensors
because when we walked in the lights were off and came on.
They have a clear understanding of the highest-energy consumers in the plant and that's the way to start.
You need to go and really apply your efforts to the biggest opportunity and they are doing it.
One of the things that I noticed in both places is how invested employees are
from the Plant Managers all the way down to the people on the line, in terms of the different
things they can do at their own levels to really make improvements that can better the whole facility.
As we toured the assembly line, what was a challenge for me was separating how interesting it was
to watch a Chevy Volt being manufactured, from then identifying and connecting
the dots of all the energy inputs that go into that manufacturing process.
What I learned here is that we have similar challenges,
but also many of those challenges have similar solutions.
None of us are as smart as all of us and if we could leverage that collective intelligence,
I think we could really bring some innovative ideas and help both factories win.
It's been really exciting to have the L'Oréal team here at our facility today.
They even brought their own gadgets like we did, and they one-upped us
with their ultrasonic meter in the powerhouse, which I thought was funny.
The fun part is having people in the facility and finding out new opportunities,
things that you don't see that they do because it's a fresh set of eyes.
We're getting really excited to find out what they found.
Through the Better Plants Challenge at the Department of Energy
we're working with national and international leaders when it comes to energy efficiency
in the manufacturing space.
So it's a lot of fun, there's a lot of sharing, there's a lot of solutions, and there's a lot of innovation.
And that's important for all of us.
Coming up in the next episode...
L'Oréal and General Motors demonstrated why they are energy efficiency
leaders in the manufacturing sector.
See what they recommend to one another and what best practices they'll take home
with them on Episode 3.
For more infomation >> 4/23/18 9:41 PM (5301 N Driscoll Blvd, Spokane, WA 99205, USA) - Duration: 1:57. 
For more infomation >> 4/23/18 9:36 PM (4532-4548 N Driscoll Blvd, Spokane, WA 99205, USA) - Duration: 4:59. 
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