Cassidian | Energy Saving

Cassidian is an EADS company employing 28,000 specialising in providing solutions for aspects of security including national security, security of deployed forces, event security, communication and network security, advanced cyber security or the security of deployed forces.

Oakland Consulting has been working with EADS over several years to develop and implement an effective improvement programme.This case study briefly describes just one of the hundreds of projects undertaken. It describes the first project undertaken by an EADS Black Belt candidate, recently trained by Oakland Consulting in Lean Six Sigma

Assignment

Energy consumption at the Ulm site of Cassidian in Germany, had been rising steadily over the preceding years. Coupled with increasing energy costs and the heightened environmental awareness of wasteful energy consumption, the Production team set about identifying potential opportunities to make better use of financially and environmentally expensive energy resources.

Approach

A multi-function team made up of the key stakeholder departments (production, engineering, facilities, environmental) initially performed a systematic analysis of the existing power usage to establish a baseline of consumption behaviour. However the team had to identify where the energy was being consumed and how they were to reduce this without compromising the performance of the site. To assist them with their project the team used the DRIVER performance improvement methodology and its range of tools at each of the phases as follows:

  • Define phase – project scoping, ‘is and is not’, brainstorming
  • Review – data collection, run charts, questionnaires
  • Investigation – Pareto analysis, waste identification
  • Verification – Prioritisation matrices, benchmarking
  • Execution – Control charts, multiple communications
  • Reinforce – Employee involvement, KPI monitoring

EnergySaving Case Study 1

Achievements

This initially led to some ‘quick wins’ in terms of easily resolvable wasteful practices and the development of a ‘peak load’ management protocol.

Further investigations found that some high users of energy (air-conditioning and compressors) could significantly reduce their power consumption with more effective alignment of their running time with need without compromising the user. More visible but relatively low consumers of energy (lighting and IT equipment) were also targeted as an effective means to raise awareness amongst all employees and hence influence a change in their general behaviour concerning energy consumption and the impact on the environment.

Simple low costs enhancements such as motion detectors, timers, visual management boards and others proved to be extremely effective. Within 6 months energy consumption was reduced by 9% with further reductions anticipated. With the newly acquired metrics, departmental managers now have their power consumption measured and are challenged to make year on year improvements.

The team found that the systematic phased methodology of DRIVER helped them to be focused and not to jump to solution without performing a thorough analysis of the available data. Furthermore this helped with securing the success of changing stakeholders behaviour and ensuring the gains made were going to be sustained.

EnergySaving Case Study 2