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Rockwell Collins

Year Submitted: 2015

Process: Energy Reduction

Industry: Electronics Manufacturer

Location: Cedar Rapids IA

No. of employees: 999

Contact: Brion Hurley

Phone: 321-271-5361


After compiling the corporate greenhouse gas report, the C Ave complex was identified as the largest contributor, with electricity as the largest energy source. a Six Sigma Black Belt project was launched. The team did not have a detailed breakdown of electricity by area for the Measure phase, so they were able to model the usage using a statistical regression model. The model identified the HVAC system as the largest driver. 

P2 Application:

The team worked with the maintenance team to conduct a pilot project to test out a setback program on the air handler units (AHU), with override buttons for off-hour building usage, and it was deemed a success with a short payback (under 6 months). An implementation team was created to roll out the project to over 200 AHUs within the facility. It took almost one year to complete the rollout across the large facility, but the results yielded more than $300,000 in electricity savings, with an implementation cost of approximately $50,000 for labor and materials. The reduction in electricity equated to over four million kilowatt hours (kWh), which is over 2,500 metric tons of carbon dioxide equivalent.

  • Total Cost Savings: $300,000.00
  • Comments:

Details of Reductions

Additional Information :

Savings were estimated based on the results of the pilot project, then updated after one year based on actual electricity usage. These were approved by the Facilities department who is responsible for paying all utility bills. 

I have presented this project internally to my company, and externally twice at Lean Six Sigma conferences. In addition, an article about this project was published in the Institute of Industrial Engineering (IIE) monthly magazine. A copy can be downloaded at this link:

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