Smithfield Manufacturing is a manufacturing company located in Clarksville, TN that was founded in 1952. In recent years, the company implemented lean manufacturing practices and became green certified in 2012 in order to reduce waste and save on energy costs. Through projects like installing more efficient lighting, replacing an older air compressor with a variable speed model, and using thermal equalizers, the company was able to reduce its electricity costs by 10% and save $700 per month on air compressor costs. Smithfield's efforts to become more energy efficient also helped it receive recognition as the best small business green program in 2012.

1. “Lean and Green”
Energy Savings
at
Smithfield Manufacturing
Ron Smithfield, President
Smithfield Enterprises, Inc.
237 Kraft Street
Clarksville, TN
June 13, 2013

2. Where is Smithfield Manufacturing?

4. Commercial & Military Nationwide

5. 60 Years in Clarksville
• 1952 Founded by Basil & Sue Smithfield
• 1988 Tennessee’s “Factory of the 90’s”
• 1989 started “Lean Manufacturing”
• 1999 Tornado destroyed half of plant
• 2000 BBB Torch Award for tornado recovery
• 2005, 2008 & 2011 ISO9001:2008 registered
• 2012 Green Certified

6. What do Lean and Green
have in common?

7. What do Lean and Green
Certification have in common?
1. Inputs (“Aspects”)

8. What do Lean and Green
Certification have in common?
1. Inputs (“Aspects”)
2. Outputs (“Impacts”)

9. What do Lean and Green
Certification have in common?
1. Inputs (“Aspects”)
2. Outputs (“Impacts”)
3. Goal: Minimize Waste (“3 R’s”)

10. “Lean Thinking”
• Lean =
1. right things
2. right place
3. right time
4. right quantity
5. minimize waste
6. Continuous improvement

11. Raw material to finished part

12. Machining component for Electronic
Wheel Balancer

13. Environmental Policy
1. Smithfield Manufacturing, Inc.
will institute sustainable systems
and measures to reduce waste &
pollution .

14. Environmental Policy
2. We will involve all of our team
members in being
environmentally responsible
while providing quality
components and services to our
customers.

15. SMI Goals within 12 months
(July 2011)
1. Reduce Electricity $ by 10%
2. Recycle more Metal Scrap $ by 20%
3. Reduce Oil &Coolant Disposal $ by 20%
4. Reduce Packaging $ by 10%
5. Reduce Transportation $ by 10%

16. Goal #1: Reduce Electricity $ by 10%
1. TVA audit – Replace 480 watt metal halide
lights with 277 watt T-5 electronic fixtures-
save 40%.
2. Set back thermostats for heating and cooling.
3. Turn off unused lights. Automatic lights for
safety. Motion detecting switches.

17. Before Lighting Project

18. More efficient lighting + 40% savings

19. Before

20. After

21. Lighting Project
• Pathway Lending, Nashville
• Application on line
• Terms: 5 years at 3% interest
• TVA study justified payback period < 5 years
• Installed by our maintence staff

22. Saving electricity after hours

23. Strips on overhead doors

24. Green Certification Ribbon Cutting
May 2012

25. 2012 Best Small Business
Green Program

26. Since Green Certification?
1. New high efficiency Air Compressor for
$700/mo savings
2. Replaced 20 yr old Heat Pump for office
3. Installed “Air Pears” to de-stratify heat
4. Replaced 2 old HVAC units with high
efficiency American Standard units

27. Compressed Air = Energy “Hog”
Before:
• 50 hp constant-running Air Compressor
• “Off-load” still used 60% power
After:
• 25 hp Variable Speed Air Compressor
• 40% of electricity (saving $700/month)
• Payback originally estimated at 4.5 years
• Actual payback about 3 years

28. Air Compressor Estimated Savings
1st in Tennessee for Pathway Lending

29. Variable Speed Air Compressor
QGV Variable Speed Lubricated Rotary Screw Compressor Performance
0.0
20.0
40.0
60.0
80.0
100.0
120.0
0 20 40 60 80 100 120
Percent Capacity
Percent
InputPower
% power input vs % capacity Ideal Compressor

30. Before : 50 H.P. Screw Air Compressor

31. Variable Speed Air Compressor

32. Smart Air Compressor
at only 8.6 h.p.

33. Air Drier assures clean dry air

34. 38% savings Variable speed AC

35. April 2013 vs April 2012

36. 2010 – 2013 Electricity Costs
Year Electric Costs Demand costs Demand % Comments
2010 $53,988 $11,698 22 % Baseline
2011 $51,675 $9,094 18 % Started Green
Certification
2012 $46,311 $7,587 16 % Hottest summer
28 yr
2013 (Jan-
May)
$13,856 $819 6 % Before cooling
season

37. Heat Stratification (before)
• 10 -16 degree difference ceiling to floor

38. “Air Pear” Thermal Equalizer
• Can project a column of air 50 ft.
Model 25 110 v. or 240 v.

39. “Air Pear” Thermal Equalizer (after)
• 1 – 2 degrees difference ceiling to floor
Our Results:
Team Members more comfortable & save heating cost

40. Approved for 5 years at 3% interest.
Savings greater than the monthly payment
Payback now estimated at 4 years.

41. • Tennessee companies only
• Energy savings evidence required
• Projects: lighting, HVAC, air compressors &
solar
• Payback of 5 years or less at low (2%) rates
• Loan applications at www.pathwaylending.org

42. 1. Saving $700/month with “Smart” Air Compressor
2. Saving $300/month with high efficiency lighting
3. Reduced coolant disposal by 40%
4. Reusing surplus pallets from local companies
5. Developed water saving “Meter Yoke Vise”
6. Installed “Air Pears” to de-stratify heat
7. New high efficiency HVAC units in plant
Smithfield Manufacturing

43. Energy efficiency in the office
1. Set-back thermostats
2. Replace T-12 with T-8 bulbs or T-5 fixtures
3. “Sleep mode” for computers during day
4. Turn off copiers, computers & power strips
5. Motion detectors to turn off lights
6. Double-sided printing
7. Reuse scrap paper on opposite side
8. Buy USA made products locally (if possible)

44. Lessons Learned
1. Have TVA or CDE conduct an Energy Audit
2. Apply for rebates before starting work
3. Get Team Members involved in setting Goals
4. Make Goals simple but achievable
5. Post Results very month
6. Compressed Air is expensive!
7. Use Pathway Lending to finance energy projects
8. Customers appreciate Green effort

45. Reduced Break-even = “Sustainability”

46. “The worst form of WASTE is
saying you can’t improve.”
James Womack, Lean Consultant
Question?

47. The End
Contact:
Ron Smithfield, President
Smithfield Enterprises, Inc.
237 Kraft Street
Clarksville, TN 37040-3003
(cell) 931-624-5132, (Office) 931-552-4327,
(FAX) 931-648-4460
www.smithfieldmfg.com
Email: RonSmithfield@aol.com