GM’s Energy Stars: Bob Randazzo, Rochester Operations

All this week, we will be recognizing employees from our U.S. facilities who have helped GM realized $435 million in energy savings by reducing energy intensity by 40 percent and carbon dioxide emissions by 41 percent over the last 20 years.

Name: Bob Randazzo
Title: Facilities Area Leader, Plant Engineering
Facility: Rochester Operations
Length of time with GM: 38 years

1. What led you to pursue a career in energy management?
I didn’t pursue an energy management career. It evolved out of a facility need as an additional responsibility through my time in plant engineering doing electrical work and electric power distribution, which deals with the dispersion of high electric voltage delivered from a utility service to various areas of the plant at lower voltages.

2. What benefits – financial, environmental or others – have you realized at the plant since reducing energy usage?
The main benefit is financial – savings to GM and to our facility. By reducing our operating costs, we improve our competitiveness and profitability. We also help the environment by reducing our carbon footprint.

3. What are some of the ways your facility cut energy intensity to meet the 2015 ENERGY STAR Challenge for Industry?
Rochester Operations accomplished our 29.4% energy reduction through several initiatives, including:

• Replacing lighting and using motion controls
• Upgrading heating and ventilation systems plant-wide, including replacement of our energy management control system, installation of variable speed drives, and tuning heating and ventilation unit burners for improved efficiency
• Installing energy efficient replacement windows, adding spray polyurethane foam roofing that provides a high level of insulation, and sealing doors and other openings to create a tight building envelope
• Reducing overall plant compressed air pressure and leak load and implementing small point of use compressors where possible
• Procuring new energy efficient Gen V manufacturing equipment, which incorporated things such as high efficiency motors and variable speed drives. Also incorporating energy conservation in the programmable logic controller – the computer that runs the industrial machines --  where possible.

4. How did you engage employees to cut energy use in their daily jobs?
We implemented an aggressive “Shut It Off” program to inform and encourage employees to conserve energy daily and during plant shutdowns. We also audit the process and provide feedback to departments and individuals.

5. What are some energy best practices you have learned from your colleagues, ENERGY STAR or other partners?
Keep up with energy savings technology and share your successes and challenges.

6. What is your best tip for the average consumer looking to reducing energy use – either at home or at work?
Maintain a tight envelope around your building or house by sealing doors and windows to prevent air leaks, and “Shut It Off” when not in use!