Supplier Treasure Hunt Results

1
Supplier Treasure Hunt Results

• Hosted by
• Johnson Controls INC Livermore, CA
• Trim Masters INC Modesto, CA
• DATES Nov 16 - 17

2
Participants
Rick Kalisz JCI Livermore Glen Kerrigan Amtex
INC Fred Zaske JCI Livermore Shayne Bozarth
TMI Modesto Bob Higle TMI Modesto Eddie Lucas
TMI Modesto Dan Powers TMI Modesto Joe
Mossinger TEMA Miguel Alvarez JCI
Livermore Irene Cheng TEMA
Verulo Campos Amtex INC Chris Bozzo JCI
Livermore Scott Showman TEMA Bill Brownlow
KHMCA Stanley Jackson KHMCA Marco Montalvo
TEMA Thomas Tuzinowski JCI Livermore Edward
Guzman TEMA JR Ibarra TEMA
3
Where did we look?

• Johnson Controls INC
• Foam Processing
• Trim Assembly
• Seat assembly area
• Over Head Console / Supermarket Area
• Trim Masters INC
• SK4 Seat Assembly Area
• MIG Welding Robots / Resistance Spot Welding
• Vibe Seat Assembly
• MIG Welding Robots / CNC pipe benders
• Plastic Processing Area
• Injection Molding / Plastic Assembly Equipment

4
Top 3 Kaizens
What did we find?

• Foam Line Start-up Procedure
• Fix Compressed Air Leaks
• Light Sensors by Sky Lights
• Total Estimated Energy Savings (All Projects)
• 216,728 KWh/yr
• Total Cost Savings (All Projects) 25,162/Yr
• Estimated Implementation cost 9,815
• Estimated CO2 Emission Savings 59 Metric Tons

5
Summary Report
6
Top 3 Kaizens
What did we find?

• Replace all Metal Halide lights with HID
• Injection Molding Start-up with fewer pumps
• Wayne Trail bender on during Non-Production
• Delayed start on Cooling Tower
• Total Estimated Energy Savings (All Projects)
• 778,252 KWh/yr
• Total Cost Savings (All Projects) 84,051 / Yr
• Estimated Implementation cost 57,712
• Estimated CO2 Emission Savings 214 Metric Tons

7
Summary Report
8
Questions/Comments

• Thank you!