The Lean Laboratory

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The Lean Laboratory

• Peter James, S-Lab
• (Safe, Successful, Sustainable Laboratories)
• www.goodcampus.org
• www.effectivelab.org.uk

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About Us

• Linking key laboratory stakeholders- e.g.
  researchers, lecturers, technical support,
  estates, designers suppliers
• Enabling strategic discussion of lab design,
  management and operation- identifying and
  driving improvement
• Conference and workshops
• Awards scheme
• Good practice advice/publications
• Audit and assessment tools

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2012 Award Winners

• Imperial Continuous Commissioning
• Liverpool Central Teaching Laboratory
• Loughborough Kit Catalogue
• Oldham 6th Form College Regional Science
  Centre
• Mike Foulkes/Plymouth ISO 9001
• Sheffield Hallam Cell Culture Lab
• St Andrews Chemistry Teaching
• Andrea Sella/UCL Water Efficiency

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Why Labs Will Change

• Core to STEM institutions
• Financial pressures
• Student/staff expectations
• Regulatory/stakeholder demands
• Evident inefficiencies
• More good practice examples
• Developing capability/confidence

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The Conference View

• Is there scope to significantly increase the
  efficiency and effectiveness of labs, without
  compromising quality of work or safety?- 66
  said great scope- 30 said some scope
• What would most help to achieve this?- more
  pressure from funders (60)- more focus by
  senior staff (57)- more cross-functional
  working (54)

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University of Liverpool- Central Teaching
Laboratory
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University of St Andrews- Chemistry Teaching Lab
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Imperial College- Continuous Commissioning
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The Lab as a Business

• A 10,000 m3 successful laboratory- 30
  million income streams
• A building cost of 25-30 million
• Equipment assets of 5-10 million
• Operating costs of 15-20 million
• Space costs of 300 per m2
• Utilities 500,000
• Materials/consumables 500,000
• Are assets and resources used effectively?
• Are they understood?

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Lab Energy Costs
Lab Audited GIA/m2 Electricity cost Gas cost Total Energy Cost
Liverpool - Bioscience 7,750 247,000 60,000 307,000
Edinburgh Cancer Research 3,000 152,000 48,000 200,000
York - Biology 12,740 373,000 102,000 475,000
Manchester - Chemistry 3,816 432,000 161,000 593,000
Cambridge - Chemistry 27,603 888,000 211,000 1,099,000
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Lab Energy Split ()
Bioscience Chemistry
Ventilation (including related heating) 45 60
Equipment 25 15
Conventional Heating/Hot Water 20 20
Lighting 10 5
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Freezer Energy Varies
 Model Capacity (litres) Cost per litre () Annual running cost at 7.3p/kWh
New Brunswick (Green model) 570 0.54 306
New Brunswick  (Green) 570 0.55 314
New Brunswick  (Green) 570 0.57 326
Van der Woude Revco 570 0.76 434
Lab Impex Research 570 0.85 487
Heraeus 691 0.93 641
Illshun DF8517 484 1.12 541
Kaye Sanyo  MDF-U70V  728 1.13 824
New Brunswick 101 1.79 180
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Case 2 Better Chemical Management, Edinburgh

• Tracking all chemicals through barcoded
  containers
• Users see in-house inventory when ordering
• 100,000 first year savings of chemical
  purchasing costs
• 12,000/year savings of management/disposal costs
  
• Fast access to chemicals
• Regular chemical audits
• SciQuest e-procurement links

Derek Burgess, Procurement Manager
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Lean Lab Principles Equipment and Resources

• Making issues visible
• Addressing root causes
• Right sizing
• Adjusting to needs
• Optimal efficiency
• High utilisation
• Effective management communication
• Rich information

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Leaner Cold Storage

• Making issues visible, e.g. - total cost (incl
  space, heat load)- compromised performance-
  reporting/monitoring requirements
• Addressing root causes, e.g.- storing unwanted
  samples- overly high storage temperatures- lack
  of ownership
• Right sizing- based on actual storage needs-
  standardised eqt sizes/procurement

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Leaner Cold Storage

• Adjusting to needs- appropriate temperatures
  (storage policy)- filling/blanking empty space-
  modular spaces
• Optimal efficiency- regular maintenance- cool
  locations- buying high efficiency models- chest
  rather than upright- larger models

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Leaner Cold Storage

• High utilisation- optimised containers
  racking- central services- shelf/area
  allocation
• Management and communication- cross-functional
  approach- clear responsibilities- policies
  (storage, procurement etc)- incentives (shared
  savings)
• Rich information- inventory management
  (expiry)- individual bar coding

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Leaner Chemicals

• Making issues visible- total costs (incl
  storage disposal)- waiting times-
  reporting/security requirements
• Addressing root causes- nasty chemicals, why?-
  concerns about purity
• Right sizing- smaller containers
• Adjusting to needs- microscale experiments
• Optimal efficiency

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Leaner Chemicals

• High utilisation- tracking amounts locations
• Effective management communication-
  policies- shared savings
• Rich information- computerised database

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Laboratory Energy Opportunities
Fabric lighting (LED) Wider operating
parameters Efficient/modular equipment Low
flow/alternative containment Demand
responsiveness Free cooling/heating
High efficiency equipment Eqt consolidation/sharin
g Lay out zoning Storage policies/actions Centra
l services Space efficient/natural write up
Building Services
Activities
Supply
Good understanding Effective maintenance Monitorin
g/recommissioning Right sizing Energy
awareness/incentives
Voltage optimisation/reduction High efficiency
transformers High efficiency back up Zero/low
carbon sources Thermal recovery/storage
Design Management
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Biosciences Big Energy Users

• Freezers (-20 and -80)
• Controlled environmental chambers
• Water baths
• Incubators
• Ovens
• Icemakers
• Hybridisers
• Autoclaves
• Mass spectrometers
• Laser microscopes

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Chemistry Big Energy Users

• Hotplates/heater-stirrers
• Mass spectrometers
• Gas chromatography
• Rotary evaporators
• NMRs
• Ovens
• Fridges
• Pumps
• Water baths

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Liverpool Bioscience- Equipment

Equipment Typical peak rated power (W) Energy use per unit (kWh/year) Total energy use (kWh/year) Costs (/year)
Freezer (-20) 1,000 4380 249,660 19,973
Envtal chamber 1500-2500 8760 105,120 8,410
Water bath 500 1500 3276 101,556 8,124
Incubator 850 3723 89,352 7,148
Freezer (-80) 1,200 5256 73,584 5,887
Oven 1,500 4336.2 47,698 3,816
Ice maker 2,400 10512 31,536 2,523
Hybridiser 750 3285 19,710 1,577
Incubator-shaker 1,500 2592 18,144 1,452
Thermal Cycler (PCR) 250-1600 288 9,504 760
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Equipment Energy Varies
Biological Safety Cabinet
Growth Cabinet
kWh Annual running cost _at_7.3p/kWh
Trimat 2 (Ducted) 0.44 281.37
ESCO ACZ 4D1 (recirculating) 0.33 211.03
Growth Cabinet kWh Annual Running Cost
Sanyo Fitotron 20.64 549
Percival small 26.90 716
Percival scientific 36.36 968
Sanyo 2 62.0 1,814
Conviron 92.85 2,711
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-80 Freezer Costs

• Data supplied by University of Newcastle

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-80 Freezer Costs

• For 725L freezer
• Energy ranged from 6,00021,000 kWh/y
• Costs ranged from 500 - 1800/y
• Difference 1300/y PER FREEZER!
• Procure Energy Efficient Freezers
• Energy Star label for Lab Grade freezers

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Case 5 ReplacingFreezers at Newcastle

• 725 litre freezer energy- 6,00021,000 kWh/y
• 180,000 of central funding to replace old models
• 36 -80 freezers replaced, saving 131,000 kWh
• 7 years, at 9.5p per kWh
• Reduced space, more reliable
• More for research

Clare Rogers, Director Estates Support Services
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Case 4 Improved Sample Tracking, Queen Mary

• Blizard Institute Cell Molecular Science
• Combined 8 research centres, 40 liquid nitrogen
  dewars into centralised store
• Barcode tracking standardised containers
• 50 fewer samples
• Easier sample retrieval
• Less degradation risk
• Human Tissues Actcompliance easier

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Lab Assessment

• Self-assessment tool for lab users (and estates)
• Inspired by work of LabRATS
• Building (high level) and Lab Specific Assessment
  templates
• Lab specific assessment 30 criteria in 9
  categories
• Evidence of compliance
• Best practice guidance
• 2-3 hrs per lab

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Lab Assessment categories

• Ambient conditions ventilation
• Chemicals and materials
• Cold storage
• Fume cupboards
• Lighting
• Scientific equipment
• Waste recycling
• Water
• Innovation