(124b) Plant Energy Assessments - the Six Sigma Way

As Dow has embraced Six Sigma, we have taken a new approach to looking at energy improvement opportunities. This paper outlines the approach that Dow has taken to manage and improve energy performance. Our energy management system basically consist of: 1. measuring and tracking energy performance, 2. benchmarking performance against industry, 3. defining the gap closure plan, and 4. implement the plan. This paper briefly explains the 1st element and gives a detailed explanation of how the plant energy assessments play a key role in the 3rd element: determining where the gaps are and defining the gap closure plan. The assessments are shaped as Six Sigma projects, this means that there are 4 distinct phases: Measure, Analyze, Improve and Control, each phase has predefined deliverables. The assessments are not aimed at breakthrough development, but intend to define a roadmap for improving existing facilities, leaving no stone unturned. Specific examples of the key elements of the plant energy assessment, and their results, are given.