Achieving energy efficiency goals in a dynamic manufacturing environment is both complex and challenging. Industrial facilities and processes, especially within certain sectors, often are highly energy intensive. Operations are seldom optimized due to reluctance to affect production, competing priorities, and the view that energy is an uncontrollable cost. The author will begin with the challenges facing those responsible for energy management in industrial facilities.
Adopting an organizational culture that values and supports energy efficiency is an important underlying aspect of energy management in a company. The author uses specific examples of successes from small, medium, and larger companies. This includes the reasons why a company should adopt an energy efficient culture, the elements of Best-In-Class Energy Management, and the components of a successful program.
The paper will also discuss how to link energy management and lean manufacturing principles and initiatives that will strengthen the continuous improvement culture. This includes how to integrate energy into the value stream map; identify, quantify and estimate energy use at each point along map; develop waste, recovery and alternate technology opportunities, and create a “future state” energy map. Instructive case studies will be presented involving several manufacturing sectors including: food processing, plastics, paper, aerospace, chemical, and engineered products.
Finally, the author will close by presenting somekeys to success in adopting an energy efficient culture and integrating an Energy Management System (EMS) to yield measurable results in manufacturing.