Navistar
Melrose Park, Illinois
Intern: Roxana Kolatek
University of Illinois, Chicago
Navistar's Melrose Park plant is a diesel engine manufacturing facility, as well as an engine research and development center. Navistar employs a total of 1,490 employees in the 2.2 million square foot facility. This facility is split into two divisions: diesel engine manufacturing and engine engineering.
During the three month intern program, the intern was able to identify and and recommend several projects to decrease Navistar's energy consumption. Together these projects have the potential to save the company $773,000 annually.
Results:
The intern completed the following tasks:
- Created an air leak detection and repair program for compressed air systems at the facility. The intern identified and repaired leaks during the July shutdown, resulting in a savings of $39,000 annually. If all identified leaks are repaired, the facility could save over $92,000 a year.
- Proposed to update all incandescent exit signs to Siltron LED exit signs. This project could save $1,400 a year.
- Conducted a plant lighting audit during all shifts and proposed that lighting be upgraded to T8 fixtures. This project could lead to a $648,400 annual energy savings, with an annual reduction in CO2 emissions of 3,350 tons.
- Delamped all T17 lighting fixtures and every third High Pressure Sodium fixture. This project will lead to annual savings of $92,000.
- During the intern's plant audit, it was noticed that basement lighting was on during all shifts. Basement areas are mostly unoccupied during 2nd, 3rd and weekend shifts. The intern proposed to install corner mounted occupancy detectors. This will lead to annual savings of $7,000.
- Turned off lighting in vending machines, leading to an immediate annual savings of $1,700. The intern proposed that VendingMisers and SnackMisers be installed in all vending and snack machines. This could save the company $2,800 a year.
- There are 300 personal ventilation fans in the east side of the manufacturing plant, each of which operates during all shifts. The intern proposed replacing these fans with 24 Powerfoil X Big Ass Fans. Replacing the personal fans could result in annual savings of $20,996, with an annual reduction of 605,664 lbs in CO2 emissions.
- Created an infrared spectroscopy library of metal working fluids and separated the Spill Prevention and Countermeasure Control plan from the ICP, both of which have increased facility productivity.
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