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McKinsey
Capability
Center
GREEN
CAMPUS
FOREWORD
Mads Lauritzen
McKinsey Green Campus Global Leader
+2% p.a.
+2% p.a.
1995
1996
1997
1998
1999
2000
2001
2010
2011
2012
2013
2014
2015
2016
2017
2018
2019
2020
2021
2022
2023
2024
2025
2002
2003
2004
2005
2006
2007
2008
2009
60
40
20
0
1995
2000
2005
2010
2015
2020
2025
Failed
trans
65
formations
35
Successful
transfor mations 2
Unit of measure
Text
10
20
30
40
50
Aluminum
Steel
Cement
Coal mining
Metal ores
mining
Chemicals
Pulp and
paper
Glass
Oil refining
Food and
beverage
* Footnote
Source: Source
Failed
transformations
90
10
Successful
transformations
4. Misalignment of aspirations
across organization
How do I establish a
substantial,
scalable, and
sustainable
transformation approach?
Management
system
The technical
processes,
decision support
tools, systems
and resources
that create value
The formal
performance
management tools
and systems (e.g.,
metrics, meetings,
roles) supported by
the right
organization
structure to drive
results
People
system
The right people with the right
skills, mindsets, behaviors and
ownership, both individually and
collectively
Books and
PowerPoint
Simulations
and games
32%
Knowledge by
Hearing
65%
65%
McKinsey
Capability
Center
10%
Learning by
Shop floor
training
Seeing
GREEN
CAMPUS
Doing
Doing
A snapshot of what
you will see when
you visit McKinseys
Green Campus in
Singapore
The Green Campus leverages the
Chemical Process Technology
Centre, which is wholly managed
and operated by Petrofac Training
Services.
Package 2: Heat Exchangers
Create understanding of impact of
circuit design and maintenance on
heat transfer efficiency
Demonstrate impact on parameters
by changing flow
Package 3: Distillation
Understand requirements to
maximize profits by optimal
distillation
Understand operational costs &
tradeoffs required to achieve this
Package 1: Furnace
Create understanding of waste in
energy transfer in furnace
Demonstrate levers to improve
furnace efficiency
Conduct live, interactive changes to
realize impact
Cross-functional role-plays of
business case
Proprietary database of
energy saving levers
s in 2009 $)
2005
+2% p.a.
Instant estimation of energy
and CO2 savings
Detailed explanation on
how to execute lever
2010
2015
2020
2025
End-to-end project
management of initiative
Industry
sector
Steel
10
20
Impact achieved
Min
Max
30
40
11
09:00 am
Check-in with Omcos
CEO and track progress
against 30% energy
efficiency target
11:00 am
Participate in lecture to
learn how to identify
and quantify energy
losses on the shop floor
12
01:00 pm
03:00 pm
06:00 pm
08:00 pm
10:00 am
09:00 am
Check-in with Omcos
CEO and track progress
against 30% energy
efficiency target
11:00 am
Participate in lecture to
learn how to identify
and quantify energy
losses on the shop floor
01:00 pm
03:00 pm
06:00 pm
08:00 pm
Pool together best practices, share key lessons
learnt, and build relationships with colleagues and
faculty
pm
Accreditation of fieldwork
leads to lasting results
The Green Campus energy efficiency certification
system is a structured pathway to black belt level
that consolidates learning at every stage and
ensures lasting results of Green Transformations.
Green
Architect
Sr. Expert
Green
Expert
Green
Practitioner
0-6 months
Practicing
Learn by doing
following an
expert
14
6-18 months
Teaching
Coach others
without leading
18-36 months
Maintaining
Mentor larger
group of
experts and
maintain
knowledge
36+ months
Architecting
Design
integrated
people and
transformation
programs
15
4,000
2,400
300
20
2
16
Consumer
goods/retail
Financial
institutions
Technology
Pharma/
healthcare
Oil refining
Pharmaceuticals
Metals processing
Gas processing
Power generation
Petrochemicals
District cooling
Large scale
food processing
Waste treatment
Change
Leaders/
Middle
Managers
5-day end-to-
22 end Kick-start
training
33 Connect &
Activate program
CASE EXAMPLE
17x
Frontline Force
27
Potential
energy savings
Estimated
program cost 1
1 Per pax cost estimation is based on Learn, Connect, & Activate SME program; actual cost may vary with the size of transformation,
number of change agents sent for program, and total number of participants per class
18
09:15
09:30
10:15
10:30
10:45
11:15
11:30
11:45
12:00
12:15
Lunch
13:00
13:15
14:00
14:30
15:00
Departure
19
19
20
Energy value
chain
T1:Energy va luechain
Theenergyvaluechainisaframeworktohelptrackenergy
throughasysteminasystematicandexhaustivemanner
Howisenergy
Purchase
purchasedfromutilitycompa nies?
consumedbyitsf inalendusers?
Makeup
Transportation
Consumption
Sales
Interaction
SOURCE: Mc Kinsey
Energy loss
framework
Acrossthe3avenues,wemustthensearchforthe9distinct
cau sesofenergyloss
Lo s ses
IN
1. Sub o pti ma l
en ergy s ou rce
U sageof su bop tim altype o f en ergy for pr oces s e. g., die selu se d
i ns tead o fgas infur nace, ga swi thlo w he atco nte nt us ed
2. Sub o pti ma l
ra w mat eri al
U sageof raw m ateri al s wh ichla ckreq uired q ual iti es e.g. ,lo w
q ual ity or eu se din b las tfu rnac e , air com pres s or takinginho t air
3. Con ver si on
i neff ic ie ncy
I ne ffic ie nt tran sfe rfr omon em edi um/ lo catio n toan oth ere .g. ,
h eatlo st in n on ins ul ated p ip e
6. Exce ss iv e
Sto rag e
7. Over p roces s in g
8. Re pr oces s in g
O UT
9. Lo w re co ver y
R epr oces si ng ofoffs pec mater ial s e. g. ,faul tyo per ati ons lead in g
to p ro ducts b ei ngfed bac k int o pro du ct io ncycle
1
D escribe
Map
3
Quantify
Describe wha t
? Tr aceenergy flow
happenswith
throught heva lue
energ ya teachstep cha intobuilda
ofthevaluec hain
visualguide
Createanenergy
balanceaccounting
f or e achstepinthe
energ yv aluecha in
Consolidate
qua ntifica tionfora ll
utilitiesint oasingle
structure
Createindividua lly
forea chpurcha se d
utility
Cr ea te individua lly
foreachpurchased
ut ility
Createindiv idually
f or e achpurchased
utilit y
Createacrossunitor
pla nt
Endproduct
Qualitat ive
descr ipt ion
descriptive
sta tements
Energyflow
? Energ yflow
diagram simila rto quantification
aprocessflow
wa terfallchar t
diag ra m,but
tra cking energ y
insteadofaprocess
Utilitymatrix
sprea dsheetbased
ca lcula tor
GreenCampus
module
Energy va luechain
Cur rentsta te
analysis
Currentstate
a na lysis
Curr entstat e
a na lysis
Load curve
T5:Loadcurv e
Loadcurvescanbeoftwotypesandeachservesdifferent
purposes
Throughputbasedloadcurveissuita blefor
Energy intensit y
tSRF/100tonfeed
Ener gy intensity
t SRF /1 00tonfeed
Sampledata point s
Theoreticalloadcurve
Apr1
Ma y1
J un1
Jul1
Aug1
Theoreticallimitistheminimumamountofenergy
requiredtheoreticallyforasystemtofunction
ILLUSTRA TIV E
Energyconsumptionpe ryear
? WhereamItoday?
? Whereshould Ibe?
Des ign
losses
0 100
110
120
130
140
150
Th eoreticallimito fa
systemisits en ergy
consu mptionina
hyp oth etic alsituation
wh ereallth eenergy
in putistransferred to
an dus edbyits en d
objectivei.e.,no
energylosses
? H owfarcanIgo?
Th eoretical
limit
T6
Process parameter
analysis
Quantify operational
losses (distillation
column as example)
Date
Theoretical limit
SOURCE: Mc Kinsey
Time basedloadcurveisusefultospot
T3
? Whatarethedrivingforcesb ehindthegap ?
? HowdoIquantifyan dclosethisgap?
T5
0
Ma r1
Current state
analysis
Create energy
consumption baseline
along energy value
chain
Consolidate
Task
5. Ener gyi nt en sive ? En ergy con su mption w hile p rod uc ti on is s to pp ede. g., air
do w nt ime
c om pre ss or ru nni ng even a ft erpl ant sh ut dow n
SYSTE M
T2:Currentstatea nalysis
Followastepbystepprocessalongtheenergyvaluechainto
createtheenergyconsumptionbaseline
SOURCE: Mc Kinsey
T4
T2
160
Feed
ton
Fo otnote: SRF referstoS ta ndRefining Fuel, au nit tome asure energ ytypically use d in the re finingindustry
SOURCE: Mc Kinsey
T7
Pinch analysis
T7:Pincha na lysis
Simplifiedexampleofpinchanalysis:Currentstate
A =Steam
Feed
?
?
Pro duc t
Reactor
200C
80C
90C
B =C ooli ng
water
F ee d
Temperatu re
C
Produ ct
2 50
2 00
1 50
1 00
50
0
100
200
300
400
500
600
700
T8
Network loss
analysis
T9
Motor analysis
Quantify losses due to
inefficiencies in motors
and their applications
Quantify losses in
distribution networks
(compressed air
system as example)
80 0
Heatconten t
kW
SOURCE: Mc Kinsey
11
T10
Cost curve
T11: Costcurve
Demandprofilesaremappedversuscostcurvesbyenergy
typetoidentifypotentialtoenergycost
Demandprofile
Costanalysis
SOURCE: Mc Kinsey
Cost/Output
/MW
Maximum
demandof
250MW
Morethan175MWneed
only10%ofthetime
Boiler
3
Lessthan110MW
need50%ofthe
t ime
Boiler
4
Boiler7
Boiler6
Boiler
5
Boiler2
Boiler 1
50
Time,percent
100%=365da ys
50
SOURCE: Mc Kinsey
Fourboilersare
suf ficientto
gene rate175MW
ofst eam;7boilers
inoperation
Comparing
utilitiesdemand
overtimewiththe
utilitiescostcurve
mak esitpossible
tore ducecost
(e.g.,shutting
downboilers)
T11
T10: Ener gysourcing
Minimizingunitpriceofenergyrequiresiterationacrossutility
mix,supplierchoiceandp ricingnegotiation
Cur rent sta te
Howmuchener gy
isrequir edand
whereisitused?
W hattouse?
W ha ttypeandqualit y?
D owebuyt heutilit yor
g enerateitourselves?
2
Approachto
reduceunitpriceof
ener gy
Howmuch
topa y? 3
Howmuchtopay?
Howtoopt imize
existingcont racts?
Howtonegotiate
newcontra cts?
Energy sourcing
Determine right
sourcing strategy
T12
T12: Contracts
Atypicalenergycontracthasfourimportantelements price,
duration,offtakecommitmentandsupplyguarantees
USD/MWh
Price
Wheretobuy
from?
Whatisthe
sourcing
model?
Whatar ethe
selection
criteria?
E le ctrici ty price
H SFO 18 0 price
Du ration
0. 52 years
25years
Short
Medium
Offtake
commitmen t
SOURCE: Mc Kinsey
Lo ng
De ma n d
15
SOURCE: Mc Kinsey
l d
e r
Supply
guaran te es
O
c
w
a
U
c
U
in
16
520+ year s
Contracts
Structure and optimize
contracts
t ili t y t r i g g e r s
t e r r u p t io n c l a
n
p
t i
a
s
a
l i t y
a
p
i t
s
i t
T
u
im
s e
17
SOURCE: McKinsey
21
...management systems...
Transformation design
accelerated4by3 energyefficiencytransformation
Gre en camp uswilldem on st rate .
an en dt oen d Pr epa re
4 st ep en ergy
Bu ild bas el ine
e fficiency
t ran sfo rma tion
Diagno s e
De sign
Des ign
tr ans form atio n
ro ll ou t
Understand overall
transformation framework:
technical, management and
people systems
?
?
M2
Managementandpeoplesystemscanbediagnosedusingthe
M2:Energyperf orma ncerev iew
9dimensionsoftheEnergyPerformanceReview
ElementsoftheEnergyPerformanceReview
External
orientation
Coordination
andcontrol
Capabilities
20
M3
PerformancemonitoringcoversKPI metrics,targets
M3:Performancemonitoring
Focus of mo dule
andworkplacevisualizationinperformancemanagement
Motivation
Effective
performance
management
Performance monitoring
Action
plans
M4
Thewill andskillleveloftheorganization,andurgencyof
M4:Implementationroadmap
changecaninfluenceimplementationstrategy
Rec omm it toexcellence
Oly mpictraining
S kil l
Wha t isthe
level of
capa bil itya nd
performance
inthe
org anization?
S treng thentheteam
Orga niza ti onmustimprov e
and ha s conviction andtime
todo so
Rebuil d forthefuture
O rganizationmust
i mprove for futureg ood,
but lack s convic tion
Novice
T ak ethefield
O rg anization
is skille da nd
committed
a ndmust
e xec ute now
Getback inthe
ga me
Ca pa ble
Urgency
Long te rm
Turna round
Orga niza tionisin
immediate ne edofcha ng e
I mmediate
Resi sta nt
Wil ling
Wil l
SOURCE: McKinsey
M5
Performancedialoguesshouldbecascadedtoalllevels,
M5:Performancedia log ue
Performance dialog ue
Ca scading
performance di alogue
EXAMPLE
F requenc y
W ithinshift
S hift
D aily
W eekl y
O pe rations
M anag er
Lev el
3
S hi ftSupervi sor
2
1
Wi thinshift
dialog s
Da ily line
ma na gement
rev iew
We ek ly
performance
review
M onthly
performa nce
review
M onthly
scoreboard
Wee kl y
sc ore board
1 O n theg o performance
dia logue
Within shif t
score board
SOURCE: McKinsey
SOURCE: McKinsey
22
Performance dialogues
Develop system and
practice coaching
employees
M onthly
4
Da ily meeting at
pla ntlevel
Area Ma nager
23
T rackingme chanism
tosupporttheachievementofKPIs
24
Develop insights on
management and people
system diagnostics
21
Howurgently is
cha nge needed?
Performance
trackingand
visualization
Renewal
Howdoestheorganization
understand,interact,respond,
andadapttoitssituationand
externalenvironment?
Improved
performance
Budget,KPIs,
andtargets
Performance
meetingsand
dialogues
Execution
Howdoestheorganization
executeinaccordancewithits
strateg y?Ca ntheorg anization
performessentialtaskswithits
currentca pabilitiesand
motivationlev el?
Innovation&
Learning
Leadership
Culture&
Climate
SOURCE: McKinsey
Corrective
actions,
rewards,
andcon
sequences
Alig nment
Arepeopleatalllevelsaligned
aroundtheorga nizationsvision,
strateg y,cult ureand values?
Direction
Account
ability
Setdirection
andcontext
3clustersofhealth
P2
P1: Rootcauseproblemsolving
Thereare2bestpracticemethodsforidentifying
therootcause
2waystostructure
Description
Typicalapplication
Issuetree
Startwithproblemstatement
andbreakitdownintological
subcomponentsforanalysis
Encouragemorethoroughanalysisof
therootcause,startingfromablank
sheet
Synthesizefindingsfromeach
subcomponentsforfinal
solution
Suitablefornewproblem
whenrelativelylittleisknownaboutit
What
How
P2: Conflictmanagement
5Whys
Startwithaproblem
definitionanddrilldownon
themostimportantissuesby
askingWhy,inorderto
recognizeandaddressroot
causes
High
ElementsoftheEnergyPerformanceReview
Passive
3clustersofhealth
Assertive
Idontreallymatter
Dontexpressneeds,opinionsorfeelings
Direction
Dontspeakupevenasothersviolate
theirrights
Account
Coordination
Avoidconflictevenatowndiscomfort
andcontrol
Alignment
Takecontrolofyourownlife
Arepeopleatalllevelsaligned
Respectneeds,opinions,andfeelingsof
aroundtheorganizationsvision,
others
strategy,cultureand values?
Maintainrightsofbothpartieswhenever
possible
Dealwithconflictinhealthyways
Execution
Howdoestheorganization
Mayturn
passiveaggressiveInnovation&
Leadership
DegreeofExternal
orientation
"5Whys"isthesimplestproblem
solvingtoolandcanbeused
immediatelyontheshopfloor
performessentialtaskswithits
Aggressive
currentcapabilitiesand
motivationlevel?
Youdontreallymatter
Dontrespectneeds,opinionsorfeelings
Renewal
ofothers
Howdoestheorganization
understand,interact,respond,
Havetendencyofviolatingothers
right
andadapttoitssituationand
Willingtoriskconflicttoaddress
externalenvironment?
personaldiscomfort
Covertconflict
Low
Importantto
recognizeand
preparefor
bothcovert
andovert
conflicts
Overtconflict
Low
SOU RCE:McKinsey
Positive
relationship,
noconflict
Constructive
executeinaccordancewithits
debate
strategy?Cantheorganization
Learning
cooperation
Passiveaggressive
byothers
Idontknowwhatmatters
Capabilities
Motivation
Dealwithneeds,opinionsandfeelingsby
notdealingwiththem
Respectrightsofothersbutdislikeit,
Culture&
oftensecretlysabotagingprocess
Climate
Avoidconflictbutquietlyresentsothers
21
High
Acknowledgeofconflictbyothers
SOURCE: McKinsey
30
P3
Practice resolving
conflicts
9dimensionsoftheEnergyPerformanceReview
Fourformsofinteraction:
ability
Conflict management
Inallinteractions,weneedtobecautiousoftwoformsof
M2:Energyperformancereview
potentialconflicts
overtandcovert
Managementandpeoplesystemscanbediagnosedusingthe
30
P4
P3:Communicationandinfluencingtechniques
Theinfluencemodelencouragesmindsetandbehaviorshift
byputtinginplacetheelementsanindividualneedforchange
M3:Performancemonitoring
Iwillchangemybehaviorif
PerformancemonitoringcoversKPI
metrics,targets
Focusofmodule
Rolemodeling
Fostering
andworkplacevisualizationinperformancemanagement
understandingand
conviction
Iknowwhatis
Iseesuperiors,peersand
subordinatesbehavinginthe
newway
Setdirection
andcontext
Corrective
actions,
rewards,
andcon
sequences
Developingtalentand
skills
Performance
Ihavetheskillsand
meetingsand
dialogues
competenciesto
behaveinthenew
way
Budget,KPIs,
andtargets
Improved
expectedofmeI
performance
agreewithit,anditis
meaningful
Mindsetand
EffectiveBehavior
performanceShifts
management
Performance
trackingand
visualization
Action
plans
P4:Continuousimprovement
Communication and
influencing techniques
Learn storytelling and
influence model to
motivate organization
Continuousimprovementelements
CIelements
? EmbedCIprinciplesinleadershiproles, suchasrigorousproblem
Thewill andskillleveloftheorganization,andurgencyof
solving,andreceptivenesstoimprovementideasfromalllevelsof
Develop
1
changecaninfluenceimplementationstrategy
the organization
leaders
Rec omm it toexcellence
? Trainleaderstobestrongcoaches
Organizationi s capablebut does
nothavetheconvictionorreal
Olympictraining
Organizationhastheskill
and commi tmentto drive
pressuretoreachthenextlevel
toward longtermsuccess
? Setupdefinedescalationpathways
toimplementnewimprovement
InstillCI
mindsets
Skil l
?
?
ideasfromwithintheorganization
Takethefield
Bringexternalinnovationandnewideas
intotheorganization
O rganization
is skilledand
EmbedimprovementandinnovationmindsetsinorganizationsDNA
committed
Getbackinthe
game
Capable
andmust
Sustain
isthe
capability
3 What
level of
building
capabil
ityand
performance
inthe
organization?
Reinforcingwithformal
mechanisms
Thestructures,
processesandsystems
reinforcethechangein
behaviorIambeing
askedtomake
Continuous
improvement
Learn best practices in
sustaining ongoing
transformation impact
Examplesofactivities
M4:Implementationroadmap
Reward
achievement
Novice
Howurgentlyis
change needed?
intheline,andbuildcapabilityintheorganization throughbothformal
andonthe jobtraining
Rebuil d forthefuture
Strengthentheteam
Provideonthejobcoachingandfeedback
Organizati onmustimprove
Organizationmust
i mprove for futuregood,
but lack s convic tion
? Urgency
Linkfinancialrewards toimprovementtargets,orprovidecashprizes
forsolutionstoproblemsornewideasforimprovement
Rallytheteam
Celebrateandrecognizegoodideasthroughnonfinancialmeans,e.g.
Organizationhas
convic tion,butneeds
careerprogressionopportunities,awards,peerrecognition,networking
help tochangequick ly
opportunities,etc Wil l
Longterm
Turnaround
Organizationisin
immediateneedofchange
I mmediate
Resi stant
Wil ling
Next,welookatsomeofthestructuresyoucanputin
Howali gnedisl eadershi p, howon
placeinyourorganizationtoaccomplishtheseCIactivities
board ismiddle managementandhow
open wi llthefrontl inebe tochange?
SOURCE: McKinsey
SOURCE: McKinsey
22
23
30
SOURCE: McKinsey
33
22
SOURCE: McKinsey
23
McKinsey
Capability
Center
GREEN
CAMPUS
Supported by:
NEA
Li Yen Tan,
Petrofac
Paul Jones,
Head of Energy
Efficiency Programme Office
TAN_Li_Yen@nea.gov.sg
EDB
Kelvin Goh,
Assistant Head
Kelvin_Goh@edb.gov.sg
24