Case Study - MCS Universal

Transcription

US Government — Financial Impact Summary
Based on the estimated 15,000 treadmills operated by the US Government, the
treadmill saver® will generate greater than $17,397,878 savings per year.
– Electrical savings ~ $6,147,878 per year
– Replacement parts savings ~ $3,750,000 per year
– One extra year of life ~ $11,250,000 per year
– 2 hours of technicians time saved per treadmill per year (30,000 hours)
$1,160 added to the bottom line every year with each treadmill saver installed —
a 463% Internal Rate of Return or a 3 month payback.
Member Satisfaction • No Treadmills Down • All Green Lights • Lower Operating Costs
PRICELESS!
Executive Summary — US Military/Fort Sam Houston
Copyright © 2010-2012 Green Fitness Equipment Company, LLC. All rights reserved.
gymTOOLKIT®, Gymbo’s Gymflix® & treadmill saver® are registered trademarks of The Green Fitness Equipment Company, LLC
TM
This case study is based on the treadmills at the Joint Base Fort Sam Houston, TX. in order to demonstrate how
the utilization of treadmill savers® promotes and enhances a preventive maintenance program. The facility at
Fort Sam Houston receives over 4,000 weekly visits and the equipment is subjected to extreme abuse from
extensive use.
THE BOTTOM LINE
Utilizing all locations with an estimated of 15,000 treadmills, the treadmill saver will generate approximately
$17,400,000 savings in electricity and capital expenditures per year. Or $100,000,000 over the useful life of
the treadmills.
THE PROBLEM
Treadmills either work or they don’t, and most people think that if the belt is moving then the treadmill is
working. This is not true. Up until now, treadmills have not had the benefit of a “check engine light” to tell
them when there are issues with their treadmills.
Much like our body, when a treadmill runs too hot, it says something is wrong. By measuring amps, we can tell
when a treadmill pulls too much electricity resulting in excess heat that is damaging and can be very costly,
not to mention dangerous for the user. As the friction increases between the belt and deck, the motor has to
work harder and requires more electricity, which in turn results in increased heat that melts and destroys
electronics. Similar to a well-maintained vehicle, treadmills have an indefinite lifespan with proper service and
support.
As the most popular piece of equipment in the gym treadmills are essential to keep running strong for your
members. Almost all issues – clogged wax nozzles, worn running belts, grooved decks, excessively high
electricity bills or treadmill user injuries that expose you to personal liability – can be avoided by using the
award-winning treadmill saver.
Use
(Normal – optimal efficency)
Check
(Alert 1 – costing you more)
Case Study - US Military/Fort Sam Houston
Repair
(Alert 2 – costing you too much)
TM
FINANCIAL CONCLUSIONS
Energy Savings:
Utilizing the data from the installation and using a treadmill count of 15,000 (estimated fleet of treadmills in the
US military & US Government), the average energy savings is $1.12 per treadmill per day. Therefore, utilization
of the treadmill saver® will generate an estimated $6,147,000 savings in electricity per year.
Capital Expense Savings:
With the average cost of a treadmill being $4,500 and amortizing the cost over the current 2 year useful life
span generates a “Cap X” of $2,250 per year per machine. It is not unreasonable that by utilizing the treadmill
saver and performing regular preventive maintenance, the useful life of a treadmill can be extended by a
minimum of 1 year. This realizes a $750 savings a year per machine, a $11,250,000 “CAPX” savings across the
fleet of treadmills each year. See graph below for savings in years 4, 5 & 6.
BASED ON THIS DATA COLLECTED THE ROI OF UTILIZING treadmill saver® is 3 MONTHS – (See Exhibit B).
Savings in Principle Payments
$2,500
Annual Principle Payments
$2,000
$750
per treadmill
$1,125
per treadmill
$1,350
per treadmill
$1,500
$1,500
per treadmill
$2,250
$1,000
$1,500
$1,125
$500
$900
$750
$0
Annual CAPX Savings:
Cumulative Energy Savings:
2 Year Amo. Annual Pmt.
$0
$0
$11,735,000
$18,433,633
$16,875,000
$24,591,510
$20,250,000
$30,739,388
$22,500,000
$36,887,265
Current status – without
treadmill saver® protection
TM
Installation Date:
Facility Name:
Facility Address:
June 5th, 2012
Fort Sam Houston
Joint Base - Fort Sam Houston, TX
TESTING & INSTALLATION PROTOCOL
1. Installed treadmill savers® and ensured all cables are in good condition and clear from being crushed by
the frame and deck.
2. Set the treadmill saver alerts - yellow “alert 1” to 8 amps and red “alert 2” to 10 amps.
3. Using the red “Live Current Loop” we measured the amp draw of the treadmill at 3.5mph & 7.0mph —
with no one on the treadmill (no load), and then at 3.5mph & 7.0mph with someone on the treadmill (with
load) and noted the results.
4. If the amp reading was above 10 amps at 7.0 mph, preventive maintenance was executed according to the
manufacturers preventive maintenance recommendations. (See Exhibit B for running amperage).
6. Once preventive maintenance and/or repairs were completed the treadmill was retested. These steps were
repeated until the amps were under 10 at 7.0mph.
FINDINGS & RESULTS
• The treadmills were running at a minimum of 56% inefficiency and consequently were costing 56% more
in electricity and were the cause of the recent motor control burn outs.
• Basic preventive maintenance protocol performed (cleaning, lubricating, belt alignment and tensioning)
returned an average of 34% of the treadmills’ efficiency.
• The outstanding balance of inefficiency accounted for the accumulated damage and can be corrected
through replacements of damaged components.
• Through basic consistent preventive maintenance the current 2 year purchase cycle can be doubled if not
tripled.
MANAGERIAL BENEFITS
• At a glance know which treadmills are safe for the user.
• At a glance know which treadmills are functioning correctly.
• At a glance know which treadmills need attention and are alerting staff proactively.
• At a glance know which treadmills have been utilized for more than 150 hours and need preventive
maintenance.
• Track which treadmills are used most and which should be switched with less utilized machines providing
even wear.
• The ability to hold maintenance staff and third party vendors accountable .
ions
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TM
NATIONAL FINDINGS AS SUBMITTED TO THE DOE WITH ENDORSEMENT
IMPLEMENTING PREVENTIVE MAINTENANCE IN ALL GOVERNMENT FITNESS FACILITIES
The proposal is to implement preventive maintenance in all government fitness facilities to preserve the
equipment and specifically save electricity by monitoring and keeping all treadmills operating at peak
performance through the use of the treadmill saver®.
The electrical operating cost of our government fleet of treadmills is over 16 million dollars per year in their
current condition. Through proper preventive maintenance, service and monitoring with the treadmill saver,
the electrical operating costs can be brought down to 10 million per year, every year. We are wasting over 6
million dollars in electricity per year, over $16,000 every single day of the year. This is a 40% energy savings
with the added benefits of preserving the equipment, increasing users’ safety, extending the treadmill lifecycle
from 2–3 years to 4–6 years and enabling the government to skip a 100+ million dollar treadmill replacement
purchase cycle. Full purchase and implementation of the treadmill saver across the government fleet of
treadmills will pay for itself in less than six months ($249 per treadmill saver x approx. 15,000 treadmills = $3.75
million). The electricity savings will continue at a rate of 6 million dollars per year, every year, after
implementation. The capital budget savings per year in assuming the life extension of just one year beyond
the current useful life is a 11 million dollar savings per year.
ABOUT THE treadmill saver®
Designed, engineered, manufactured and assembled in the United States.
The patented treadmill saver connects to any treadmill, regardless of make, model, or voltage. The treadmill
plugs into the treadmill saver and the treadmill saver plugs into the wall/power source. The treadmill saver is a
completely self-contained monitoring device housed in polycarbonate shaped like a 4 – by 2 – inch puck with
LED indicator lights of green, yellow and red. The treadmill saver measures amperage draw of the treadmill
drive motor as it maintains the speed as programmed by the user. The treadmill saver averages thousands of
data samples over a 24 hour period, displaying green (if average amperage draw is below the yellow variable
set point, factory set at 8 amps), yellow (if average amperage draw is above the yellow set point and below the
variable red set point), or red (if average amperage draw is above the variable red set point, factory set at 10
amps).
Every treadmill follows the same basic design structure and the factory units are engineered to pull no more
than 10 amps even at maximum speed and user load. It is feasible that in fewer than 2 weeks of use without
proper maintenance and cleaning, treadmills can accumulate permanent damage to the electrical and
mechanical components. The friction, and subsequent heat generated, increases the load on the treadmill
motor, which is reflected in the increase in amperage/electricity draw. The treadmill saver is the only device of
its kind that enables real time monitoring with simple stoplight functionality much like a check engine light
for a treadmill. Once the treadmill saver goes yellow, cleaning and preventive maintenance need to be
employed. When the treadmill saver goes red, the treadmill needs to be serviced right away both for user
safety and to prevent permanent damage to the treadmill which can be very costly.
The treadmill saver records the hours of treadmill use and will flash when the hour count gets to 150 hours,
which is the recommended service cycle by treadmill manufacturers. Once preventive service is performed,
the hour counter can be reset to zero to be ready to notify the next service cycle. The data storage capacity of
the treadmill saver is enough for 44 years of continuous treadmill use.
TM
The average power draw for treadmills not properly maintained is 12–20 amps. With proper monitoring and
preventive maintenance, treadmills can be kept under 10 amps. The resultant electricity savings by making
the treadmill 40% more efficient is significant, upwards of $300 per treadmill, per year. Multiplied by the
number of treadmills in the government‘s inventory, the electricity savings is well over 6 million dollars per
year and falls directly in line with the President’s policy of becoming more energy independent. [Energy
Independence and Security Act of 2007, sect. 431 mandates a 30% reduction (from 2005 baseline) in energy
usage by 2015 for all DoD].
From an equipment replacement standpoint, being able to extend the lifecycle of the government inventory
of treadmills from 2–3 years to 4–6 years will save the government over $100 million in procurement by
skipping just one purchase cycle. Our test facility (an FBI fitness center) has been able to maintain their
treadmills to factory specification for 12 years, the equivalent of skipping 4 purchase cycles. Translating this to
the rest of the government’s equipment can save hundreds of million of dollars in equipment costs.
Implementation of preventive maintenance can be performed by either in-house or contract service
personnel.
The US Military has a proven track record for preventive maintenance on our airplanes, vehicles, ships,
submarines, and even buildings. By applying the same proven methods to fitness equipment the government
has already purchased will save millions of dollars in electricity, hundreds of millions in replacement
equipment and create a safe environment for all fitness facility users. Much like a well-maintained vehicle,
treadmills have an indefinite lifespan with proper service and support. The treadmill saver alerts you when the
treadmill is pulling too many amps and needs to be cleaned and/or serviced, prior to any permanent damage
done to the machine. It provides a metric for evaluating the treadmills’ efficiency and allows operators to keep
the equipment operating at peak performance.
2012
SILVER
Category:
Product Design - Professional Award
Sustainable Living/Environmental Preservation
WINNER
IDA
Sub Category:
Energy Conservation Equipment
INTERNATIONAL
DESIGN
AWARDS
TM
Exhibit A
Power Consumption Analysis of
Life Fitness Elevation Series 95T Engage, Technogym
Excite Run 900E, Star Trac P Series,
Precor 932i Treadmills and Matrix T7xe
On December 16 and 17, 2009 Intertek conducted an Energy Consumption Analysis of treadmills at Life Fitness’
facility in Franklin Park, Illinois.
Treadmill Evaluation Process:
Each treadmill was operated for a 15 minute warm-up period at a 3.5 MPH speed before recording any values.
The same user, weighing 220 lbs, operated the treadmills throughout the testing process.
The energy consumption of each of the treadmills was evaluated at four different speeds:
•
•
•
•
3.5 Miles per hour
5.0 Miles per hour
7.0 Miles per hour
9.0 Miles per hour
A tachometer was used to verify the displayed speed of each unit. The energy consumption was averaged for a
period of 30 seconds at each speed before any measurement.
Treadmill Evaluation Results
The average power consumption recorded in watts during the tests for the Life Fitness Elevation Series 95T
Engage Treadmill, Technogym Excite Run 900E, Star Trac P Series, Precor 932i and Matrix T7xe at each of the
speeds is as follows:
Life Fitness Elevation Series 95T Engage Treadmill
Technogym Excite Run 900E
SPEED (MPH)
SPEED (MPH)
3.5
5.0
7.0
9.0
AVERAGE POWER CONSUMPTION (WATTS)
284.69
303.5
354.49
572.36
2.37 amps
2.53 amps
2.95 amps
4.77 amps
3.5
5.0
7.0
9.0
Precor 932i
508.4
673.8
883.3
1082.5
4.24 amps
5.62 amps
7.36 amps
9.02 amps
Star Trac P Series
SPEED (MPH)
3.5
5.0
7.0
9.0
383.61
505.8
710.1
927.8
SPEED (MPH)
319.95
360.6
455.38
612.09
SPEED (MPH)
3.20 amps
4.22 amps
5.92 amps
7.73 amps
Matrix T7xe
3.5
5.0
7.0
9.0
3.5
5.0
7.0
9.0
343.4
550.2
645.97
872.4
2.86 amps
4.56 amps
5.40 amps
7.30 amps
Notes:
* The conversion of watts to amps assumes a consistant 120 volts.
** The conversion of watts to amps at fixed voltage is governed
by the equation amps = watts/volts.
2.67 amps
3.00 amps
3.79 amps
5.10 amps
http://www.lifefitness.com/static/cms_workspace/Energy_Savings/Energy_Efficiency_Test_Details.pdf
TM
Exhibit B
Notes:
- Data shown are the results from the installation at Fort Sam Houston
- With 80% of the treadmills, we were able to achieve a new threshold below the 8 amps
- Table shows an estimated of 3 month ROI
TM
Exhibit C
TM
Exhibit D
TM

Case Study - MCS Universal

Transcription

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