ENERGY

TRAINING MANUAL

STRICTLY CONFIDENTIAL WCM CENTRAL TEAM

 Energy
Objectives

VISION
To guarantee correct and continuous improvement of energy
comsumption and optimization, operating according to law, EN 16001
procedures and WCM energy principles.

MISSION

To create an energy-friendly plant, where each person takes

responsibility for energy consumption and actively works to reduce it

OBJECTIVES
Use new technologies and renewable sources to :
•reduce energy consumption,
•reduce CO2 emissions generated.

2
 Energy
Introduction

Mutually Exclusive and Collectively Exhaustive

“The MECE principle (mutually exclusive and collectively exhaustive) is a

grouping principle which says that data in a group should be divided into
subgroups that comprehensively represent that group (no gaps) without
overlapping.”

This principle is especially valuable for Energy and CO2 emissions

accounting and Energy losses.
According to this principle is very important avoiding the double
accounting of Energy losses.
NON MECE principle

Losses proposed in the page 30 respect MECE principle

3
 Energy
Introduction

Mutually Exclusive and Collectively Exhaustive

WARNING: THE LOSS SHOULD NOT BE COUNTED TWICE
The identified lossess and inserted into this cost deployment are associated losses with
only the energy efficiency of plants (process / general) and their management in terms of
energy.
The resulting energy losses due to anomalies related to the prodcution of parts (those
must be incorporated in the manufacturing cost deployment) are excluded.
For Example:

Losses due to obsolescence COST DEPLOYMENT

lighting system ENERGY

Losses due to prolonged COST DEPLOYMENT

power plant for reworking MANUFACTURING
plates

4
Energy
Seven Steps of Energy Saving

Step 7

7. Horizontal
Step 6
expansion
Step 5 6. Standardization

Step 4 5. Countermeasures

Step 3 4. Analysis
Step 2 3. Measurement
(local)
Step 1 2. Investigation

1. Selection of model areas (perspective)

5
Energy
Step 1

Step 7

7. Horizontal
Step 6
expansion
Step 5 6. Standardization

Step 4 5. Countermeasures

Step 3 4. Analysis
Step 2 3. Measurement
(local)
Step 1 2. Investigation

1. Selection of model areas (perspective)

6
 Energy
Step 1
Selection of model areas (perspective)

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• Appoint a responsible person for the energy issues and form an organization including finance for
them. Provide adequate financial, technical and administrative supports for the role
• Identify the energy issues (electric, gas, etc.) the plant must deal with and rank/prioritize them
• Calculate economic impact by dealing with the identified energy issues. Make a Pareto for energy
consumption (Electric, gas consumption, etc.)
• Audit the processes in the operation from an energy consumption perspective
• Use the output from this audit to prioritize energy issues according to potential energy
consumption reduction as well as according to the possibility of action to reduce energy
consumption.
• Select the major energy consumption sources and choose areas, or blocks an processes to attack
the identified energy issues
• Rank line/equipment based on energy consumption
• Select of production line/equipment consuming much energy
• Choose equipment which has a high possibility of horizontal expansion of the know-how created
to other line or equipment
• Choose line/equipment which has high energy consumption unit even at the time of reduced
production
• Set the objectives and targets

7
 Energy
Step 1
Selection of model areas (perspective)

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Nominate an Energy Pillar Leader and establish an Energy Team with skilled people
Energy Leader (Who can be the Energy Leader?)
Should be the responsible of the energy in the plant-wide.
Energy Organization (Who has to be in Energy Team?)
EN Pillar
Model Area Finance Leader
Team Leader

Energy Manager

Production
Facility Responsibles from
Maintenance
Responsible each Processes
Responsible
If he/she is not the same
as Energy Manager

8
 Energy
Step 1
Selection of model areas (perspective)

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Identify Energy carriers in the plant according to Energy Flow.

Which types of energy are necessary to produce a product?

Where does the energy come from into our Plant?

Transmit Transmit
Energy Source Transformation Point of use

The part of the generation The facility that transforms The type of energy used in
that is only for those who the energy from one type to the plant
are the owner of the plant another type which is used
into the plant.

Transformer Station

Boiler

Compressor

Heater

Air Conditioner

Lighting

9
 Energy
Step 1
Selection of model areas (perspective)

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Identify Energy carriers in the plant according to Energy Flow.
Energy
Transformation Point of use
Source Transmit Transmit
Example

10
 Energy
Step 1
Selection of model areas (perspective)

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Rank Energy carriers in the plant
Example

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 Energy
Step 1
Selection of model areas (perspective)

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Stratify and rank/prioritize the energy consumption of processes/Units/equipments. Select the line/equipment
which has high energy consumption.
Example PARETO OF ENERGY CONSUMPTION
Water
7.000.000
High Energy Consumption 6.000.000
5.000.000
4.000.000
Heating
3.000.000

PLN/Yr
2.000.000
1.000.000 Air
0

Lighting

12
 Energy
Step 1
Selection of model areas (perspective)

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Select the line/equipment which has high possibility of horizontal expansion
Example
High Possibility of Horizontal Expansion
Number of CNC

Number of Transfert Lines

Number of Washing Machines

Number of Automatic Assy Stations

Number of Conveyors

13
 Energy
Step 1
Step 1 requires the identification of the model area: to do that we need to know the
flows of energy carriers within our plant

14
 Energy
Step 1

PRIORITY AREA

FUTURE
CRITERIA AREAS

High
Consumption

High
Expandibility

HIGH CONSUMPTION XXXX XXX XX X X X X

HIGH EXPANDIBILITY XXXX XXX XXX X

15
 Energy
Seven Steps of Energy Saving

Step 7

7. Horizontal expansion
Step 6

Step 5 6. Standardization

Step 4 5. Countermeasures

Step 3 4. Analysis

Step 2 3. Measurement/Training/Auditing

Step 1 2. Investigation

1. Selection of model areas

16
 Energy
Step 2

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Investigation

2.1 Investigation of line/equipment

• Investigation of the outline of the process
• Investigation of the equipment system
• Investigation of equipment capacity

2.2 Investigation of the operation situation

• Investigation of the set condition
• Investigation of the production situation and operation situation

17
 Energy
Step 2

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Investigation

Key questions to get detailed information in the Model Area

• What is the equipment? (Electrical motor, boiler, etc.)

• Where is located?
• When is used? (Always, during production, NPP)
• Who uses/manages it?
• Why is used?
• How much energy is consumed?

Make sure to include:

• Consumption driver (which factors influences the consumption.
• Installed power
• Function mode (always operating, operating when production etc.)
• Saturation

18
 Energy
Step 2

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Investigation

Example

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 Energy
Step 2

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Investigation

Example

Results

Transfer Bar motor works even after transfer and when the production is stopped

Axis motor works even after transfer and when the production is stopped

Hydraulic system motors function also during production break or when the production is stopped

PEL valve enabled always, during part clamping and during production stop

20
 Energy
Step 2

1K
4K

D09

MANUFACTURER EQUIPMENT ID NOMINAL VALUES COMPONENTS OF

EQUIPMENT

21
Energy
Step 3

Step 7

Step 6 7. Horizontal expansion

Step 5 6. Standardization

Step 4 5. Countermeasures

Step 3 4. Analysis

Step 2 3. Measurement/Training/Auditing

Step 1 2. Investigation

1. Selection of model areas

22
 Energy
Step 3
Measurement (local)/education and training/auditing

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• Choosing measuring points and effective measurement methods
• Understanding the fixed part and the variable part of energy
consumption
• Investigation of the theoretical consumption rate and actual rate and
its gap analysis
• Understanding the situation of energy consumption over time
• Employees energy awareness (communications, brochures)
• Educate and train people to save energy
• Establish an audit system

23
 Energy
Step 3
Measurement (local)/education and training/auditing

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Fix and Variable part of Energy
A certain amount of energy is consumed whenever you are producing or not. This amount is the fix consumption
and could be evaluated through the indicator “C0” which name comes from “Consumption at zero production”.

24
 Energy
Step 3
Measurement (local)/education and training/auditing

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There are two investigation drivers to optimize the energy

ENERGY OPTIMIZATION

FLEXIBILITY EFFICIENCY
(No production, No consumption) (Same production, Less consumption)

Link consumption to production Correct set-points

Reduce Energy consumption during NPP Reduce leakages

Scheduling of production energy-oriented Energy-oriented equipments

25
 Energy
Step 3
Measurement (local)/education and training/auditing

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Flexibility

Make Energy to be Proportional to Production

Energy consumption is not directly related In the ideal world Energy consumption is
to production volume directly related to production volume
Energy (Gj)

Energy (Gj)
Production Production

26
 Energy
Step 3
Measurement (local)/education and training/auditing

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Efficiency

Produce more consuming less

Energy (Gj)

Production

27
 Energy
Step 3
Measurement (local)/education and training/auditing

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Measurements
Example

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 Energy
Step 3
Measurement (local)/education and training/auditing

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S7
Fix and Variable Part
Example

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 Energy
Step 3
Measurement (local)/education and training/auditing

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S7
Auditing

30
Energy
Step 3

D09

31
 Energy
Step 3
Operating Unit ECU mid volumes Measurement of each
equipment:

Front end
line

Back end
line
Middle
end line

32
 Energy
Step 3
Installation of electric energy measurement instruments:

Plant Starting
Plant level
situation 5

Operating Unit ECU mid volumes

Investigatio
40 +1 n area

Operating Unit High Operating Unit Operatin

g Unit
Extension
volumes ECU mid volumes
Clean
Room 80 +1 areas
Operating Unit cluster HL + ML Operating Unit Cockpit

Operating Unit
dials screen Operating Unit Moulding
printing

33
 Energy
Step 3
Implementation of EM&T :

N° 120 instruments
for electric energy
N° 2 instruments for
wells water

N° 2 instruments
for compressed
air
N° 5 instruments
for hot water

134
N° 5 instruments Instruments
for natural gas installed

34
 Energy
Step 3

Automatic data collection

Implementation of EM&T

Local measurement
datas

Complete EM&T
system

35
 Energy
Step 4

Step 7

Step 6 7. Horizontal expansion

Step 5 6. Standardization

Step 4 5. Countermeasures

Step 3 4. Analysis

Step 2 3. Measurement/Training/Auditing

Step 1 2. Investigation

1. Selection of model areas

36
 Energy
Step 4
Analysis

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• Classification between the fixed part and the variable part
• Utilization situation during breaks (lunch, pause, etc.), between shifts,
over nights and on holidays
• Identification problem
• Identification of possible solutions for reduction of energy losses

37
 Energy
Step 4
Analysis

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i. 7 Types of Losses
Type 1: Losses due to useless consumption Type 5: Transmission losses
a. Non-productive periods a.Leakages
b. Stand-by b.Low insulation
c. Non-necessary users c.Dispersions

Type 2: Losses due to over consumption Type 6: Transformation losses

a. Set point too high a.Technical efficiency
b. Lack of maintenance
c. Equipment not working in design-conditions

Type 3: Losses due to non-optimization Type 7: More efficient / convenient / sustainable

a. Low saturation energy source
b. Over/Under-engineering a.Photovoltaic
c. Obsolescence b.Geothermal
c.Cogeneration
Type 4: Losses due to not using recoverable energy d.Solar Energy
a) Residual thermal energy e.Others
b) Residual kinetic energy

38
 Energy
Step 4
Analysis

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i. 7 Types of Losses

Transmission
Energy Source Transformation Point of use

Type 7 Type 6 Type 5 Type 1

Type 2

Type 3

Type 4

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 Energy
Step 4
Analysis

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i. 7 Types of Losses

Point of use

Losses due to useless consumption:

Type 1 • Stopping the equipment when not in use
• Stopping computer, P.C. when not in use for more than 20 min
• Turned off lighting when there is no people (toilets, etc.)
• Using low emission polyester thin thermal film to prevent heat from going out through
windows

Losses due to over consumption:

Type 2 * Classify energy consumption into fixed part and the variable part and taking countermeasures
to make energy consumption of the fixed part to be proportional to the production

Losses due to non-optimization:

Type 3 • Using inverters
• Narrowing the gap between the exact amount of energy needed and actual consumption

Losses due to not using recoverable energy:

Type 4 * Using heat exchangers

40
 Energy
Step 4
Analysis

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i. 7 Types of Losses
Transmission
Transformation Point of use

Type 5 Leakages loss reduction:

•Electric non-conductance
•Thermal insulation
•Air leakage elimination
•.....

41
 Energy
Step 4
Analysis

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i. 7 Types of Losses

Energy Source Transformation Point of use

Electrical Energy Equipment Driving Force

Electrical Energy Boiler Steam

or Gas
Electrical Energy Compressor Pneumatic Pressure
Electrical Energy
Heater Heat
or Gas

Electrical Energy Air Conditioner Cool Air

Light
Electrical Energy Lighting
(eg. LED for lighting)
Technical Efficiency:
Type 6 * Efficiency improvement by better technologies

42
 Energy
Step 4
Analysis

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i. 7 Types of Losses

Energy Source Transformation

Type 7
Change from;
•electric to gas
•electric to cogeneration, tri-generation (Maintenance cost is high)
•gas to biomass
Change into;
•renewal energy
•hydra-electric power
•wind energy
•photovoltaic power
•solar tube for lighting
•fuel cell, etc.

43
 Energy
Step 4
Analysis

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ii. Measurement of 7 Types of Losses
Type 1: Losses due to useless consumption
Example
40.000,0
Obszar obróbek Galeria Techniczna kWh
35.000,0
Obszar obróbek Korpus silnika kWh
30.000,0
Obszar obróbek Wał silnika kWh
25.000,0
Obszar obróbek Głowica silnika kWh
20.000,0
Obszar obróbek Oświetlenie hala niska
kWh
SUNDAY

15.000,0
Obszar obróbek Termowentylacja hala
niska kWh
10.000,0
Obszar montażu Montaż kWh
5.000,0
Obszar montażu Hamownia kWh
0,0
2011/04/01 2011/04/02 2011/04/03 2011/04/04 2011/04/05 2011/04/06 2011/04/07 2011/04/08 2011/04/09 2011/04/10

44
 Energy
Step 4
Analysis

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ii. Measurement of 7 Types of Losses
Type 2: Losses due to overconsumption
Example

45
 Energy
Step 4
Analysis

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ii. Measurement of 7 Types of Losses
Type 3: Losses due to non-optimization
Example

46
 Energy
Step 4
Analysis

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S7
ii. Measurement of 7 Types of Losses
Type 4: Losses due to not using recoverable energy
Example

47
 Energy
Step 4
Analysis

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S7
ii. Measurement of 7 Types of Losses
Type 5: Transmission losses
Example
Electrical Energy

Compressed Air

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 Energy
Step 4
Analysis

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ii. Measurement of 7 Types of Losses
Type 6: Transformation Losses
Example

Electrical Energy to Driving Force

Electrical Energy to Compressed Air

49
 Energy
Step 4
Analysis

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ii. Measurement of 7 Types of Losses
Type 7: More efficient / convenient / sustainable energy source
Example

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 Energy
Step 4
Analysis

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Example
Transmission
Energy Source Transformation Point of use

Natural Gas Boiler Heat Exchanger

Emission to the
atmosphere

Temperature set point

Air from the air sent inside the
Burners outside building (T set 20°C T
required 18°C)

Air from the Hot air into the

plant plant
Cold Water

Hot Water

51
 Energy
Step 4
Analysis

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Example
Transmission
VHP 06 Natural
Boiler Heat Exchanger
gas

Type 6: Efficiency of the Type 1: The machines

Type 5: Lack of
Type 7 actual boiler = 85% lower
than condensation boiler
insulation in the aren’t stopped during
pipes not working period
> 100%

Type 2: The set point of

air is too high (20°C vs
18° requested)

Type 3: Heat exchanger

of the machines are
dirty (worst heat
transmission)

Type 4: Part of heat is

lost because it’s not
recovered using
destratifiers

52
 Energy
Step 4

For the determination of losses we used the mece analysis that allowing us to avoid
overlaps and make logical the losses accounting

MUTUALLY
EXCLUSIVE

COLLECTIVELY LOSSES DUE ME

TO NOT RECOVERABLE

EXHAUSTIVE ENERGY CE

53
Energy
Step 4
5 Transmission: -Leakage in
compressed air net

7 More 6 Transformation
efficient/convenient/ losses:
sustainable energy -Low coefficient of
source: performance in chilled
water production 1 Unecessary
- Trigeneration
consumption:
- Low efficiency in
compressed air -Non Productive
production periods
2 Overconsumption:
-Overcharge
3 Lack of
optimization:
-Oversizing
4 Lack of recoverable
energy use:
-Residual thermal
energy
Mutually Exclusive
Collectively Exhaustive - Residual kinetic
energy

54
 Energy
Step 4
Actual Vs Ideal
Real Vs Ideal

€ 250.000

€ 200.000
7 TYPES OF ENERGY LOSSES
Step 4

€ 150.000
REAL
ACTUAL
[€]

Step 3

IDEAL
€ 100.000
Step 2

€ 50.000

€0
ELECTRICAL STEAM NATURAL GAS WATER
ENERGY
[Vettori]

MECE PRINCIPLE
(Mutually Exclusive and Collectively Exhaustive)

55
 Energy
Step 4

D09

TYPE 1: USELESS
CONSUMPTION (STAND BY)

56
 Energy
Step 4

Work
P in P out
CycleTime
Energy

Energy
Time Time
Actual energy consumption Needed energy
P loss
TYPE 3: NON
Ploss = Pin - Pout OPTIMIZATION

Energy
Time
Energy losses

57
Energy
Step 5

Step 7

Step 6 7. Horizontal expansion

Step 5 6. Standardization

Step 4 5. Countermeasures

Step 3 4. Analysis

Step 2 3. Measurement/Training/Auditing

Step 1 2. Investigation

1. Selection of model areas

58
 Energy
Step 5
Countermeasures

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• Energy cost deployment
• Careful evaluation of B/C is needed when it comes to investment of better
technologies
• Development of the system of stopping the equipment in case of no
production (Type 1)
• Countermeasures to make energy consumption of the fixed part to be
proportional to the production (Type 2)
• Reduction of the fixed part itself
• Optimization of energy consumption (Type 3)
• Pursuit of recovery of energy (Type 4)
• Countermeasures against various types of leakage (Type 5)
• Efficiency improvement by better technologies (Type 6)
• Reduction of energy consumption using other means (Type 7)

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 Energy
Step 5
Countermeasures

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Cost Deployment of Energy
A Matrix : Identify wastes and losses

List of primary energy

carriers (for generation)
and secondary (used)
with code EM & T 7 Types of Losses

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 Energy
Step 5
Countermeasures

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Cost Deployment of Energy
A Matrix : Identify wastes and losses

Processes in the plant

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 Energy
Step 5
Countermeasures

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Cost Deployment of Energy
The Complete list of EM & T
USAGE GENERATION

These lists are useful to decide what kind of

energy vectors are in the plant.

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 Energy
Step 5
Countermeasures

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Cost Deployment of Energy
B Matrix : Separate causal losses and resultant losses

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 Energy
Step 5
Countermeasures

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Cost Deployment of Energy
C Matrix : Translate identified losses into costs

64
 Energy
Step 5
Countermeasures

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Cost Deployment of Energy
Example

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 Energy
Step 5
Countermeasures

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Cost Deployment of Energy
Example
A Matrix HEAT STATION

Heat exchanger
Processes

Pump 1

Pump 2
Boiler 1

Boiler 2

Pipes
Fans
Losses

Type 1: Losses due to useless consumption X X X X Processes and

VHP06 Purchased Natural Gas

Energy Type 2: Losses due to over consumption X X machines present in

vectors Type 3: Losses due to non-optimization X X the plant (it is
according Type 4: Losses due to not using recoverable energy X X possible to add or
to EM&T Type 5: Transmission losses X eliminate
codes. It is Type 6: Transformation losses 7 type of losses processes/machines
possible to Type 7: More efficient / convenient / sustainable energy source adding or
add or X X eliminating
Type 1: Losses due to useless consumption
eliminate columns)
VH019 E.E. Driving Force

Type 2: Losses due to over consumption

vectors X
Type 3: Losses due to non-optimization
adding or
Type 4: Losses due to not using recoverable energy Indicate which type of losses on
eliminating
Type 5: Transmission losses which process with the level
lines)
Type 6: Transformation losses
Type 7: More efficient / convenient / sustainable energy source

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 Energy
Step 5
Countermeasures

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Cost Deployment of Energy
Example
Separation of Causal and Resultant Losses

Equipment involved Causal Loss Resultant Losses

Type 1: Losses due to useless VHP06 Purchased

Boiler consumption: Non-necessary Natural Gas
users

Loss on Boiler

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 Energy
Step 5
Countermeasures

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Cost Deployment of Energy
Example
Separation of Causal and Resultant Losses

Equipment involved Causal Loss Resultant Losses

Pump for Heat Type 1: Losses due to useless

VH019 E.E. Driving Force VH034 Heating for
consumption: Stand-by
Distribution Technical Continuous
Water

Loss on the Pump Loss on Heat

Exchanger

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 Energy
Step 5
Countermeasures

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Cost Deployment of Energy
Example
Separation of Causal and Resultant Losses

Equipment involved Causal Loss Resultant Losses

Heat Exchanger Type 3: Losses due to non- VHP06 Purchased

optimization: Lack of Natural Gas
maintenance

Loss on Heat
Exchanger

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 Energy
Step 5
Countermeasures

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Cost Deployment of Energy
Example
Separation of Causal and Resultant Losses

Equipment involved Casual Loss Resultant Losses

Pipes Line form the Type 5: Transmission losses: VHP06 Purchased

Low insulation Natural Gas
Boilers to the
distribution system
Loss on Pipes

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 Energy
Step 5
Countermeasures

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Cost Deployment of Energy
Example

Energy vectors present in a Process and in its

equipments/machines (it is possible to add or
eliminate energy vectors adding or eliminating
columns)

Detailed description of Detailed description Indicate the relation between

equipments/machines/facilities of causal losses Causal and Resultant Losses
involved

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 Energy
Step 5
Countermeasures

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Cost Deployment of Energy
Example
C Matrix

VHP06 Purchased Natural

VH019 E.E. Driving Force

VH018 E.E. Lighting
Quantification of the losses identified in B matrix and
Causal
amount of total losses for each energy vector

Gas
Process Equipment Losses
Type 1: Losses due to useless consumption: Non-necessary users 5.000

Boiler 1 Type 2: Losses due to over consumption: Set points too high 7.000

Type 4: Losses due to not using recoverable energy: Residual thermal energy 8.000
HEAT STATION

Type 1: Losses due to useless consumption: Non-necessary users 5.000

Boiler 2 Type 4: Losses due to not using recoverable energy: Residual thermal energy 8.000

Type 2: Losses due to over consumption: Set points too high 7.000

Pump 1 for Heat distribution Type 1: Losses due to useless consumption: Stand-by 1.000 1.500

Pump 2 for Heat distribution Type 1: Losses due to useless consumption: Stand-by 1.000 1.500

Heat Echanger Type 3: Losses due to non-optimization: Lack of maintenance 3.000

Pipes Line 1 and Line 2 form the Boylers to the distribution system Type 5: Transmission losses: Low insulation 4.000

Old Fan Engines with low efficiency Type 3: Losses due to non-optimization: Obsolescence 3.000

Detailed description of Detailed description Loss amounts

equipments/machines/facilities involved of causal losses

72
 Energy
Step 5
Countermeasures

S1
S2
S3
S4
S5
S6
S7
Cost Deployment of Energy

After the creation of Energy A, B and C matrix, the Energy Cost Deployment analysis
continues using D, E, F, G matrix common to all the pillars.
D Matrix Identify methods to recover wastes and losses.
E Matrix Estimate costs for improvement and the amount of possible cost reduction.
F Matrix Establish improvement plan and its implementation; follow up of results
achieved.
G Matrix Base for the Budget year N+1.

73
 Energy
Step 5
Countermeasures

S1
S2
S3
S4
S5
S6
S7
Cost Deployment of Energy
Example

74
 Energy
Step 5
Countermeasures

S1
S2
S3
S4
S5
S6
S7
Cost Deployment of Energy
Example

75
 Energy
Step 5: CD
All plant processes
B matrix is created for
each identified process
Process
Equipment
All EMT energy types

Energy Vector
7 types of losses

7 types of losses
Energy Vector
Equipment
7 types of losses Process

76
76
 Process
Equipment
Energy Vector
7 types of losses
Energy
Step 5: CD
All EMT energy types

77
77
 Energy
Step 5: Type 3 CD Structural project

BEFORE AFTER

A A
4,7
B
K€/Month
B/C: 0,5

Purple area: energy needed to move fluid without Green area: energy saving due to inverter
electric adjustment application

78
Energy
Step 6

Step 7

7. Horizontal
Step 6
expansion
Step 5 6. Standardization

Step 4 5. Countermeasures

Step 3 4. Analysis
Step 2 3. Measurement
(local)
Step 1 2. Investigation

1. Selection of model areas (perspective)

79
 Energy
Step 6
Standardization

S1
S2
S3
S4
S5
S6
S7
• Analysis of the mechanism of energy consumption
• Creation of good lesson of energy saving
• Creation of manuals to introduce an energy saving program

80
 Energy
Step 6
Standardization

S1
S2
S3
S4
S5
S6
S7
Analysis of the mechanism of energy consumption
Example
Total energy consumption / Engine

200.000
2010

175.000

150.000 2016

125.000 Variable
consumption
Energy [GJ]

100.000

isoperimetro
75.000

50.000 2010
2016
25.000 Fixed consumption
0
0 100.000 200.000 300.000 400.000 500.000
Engine (number)

81
 Energy
Step 6
Standardization

S1
S2
S3
S4
S5
S6
S7
Creation of good lesson of energy saving
EEM
Assessment of Energy consumption of new equipments (LCC) Example
Create energy MP-info
Green Procurement
Increase the number of checklist items

82
 Energy
Step 6
Standardization

S1
S2
S3
S4
S5
S6
S7
Creation of manuals to introduce an energy saving program
1. Building
1. Building Structure
2. Energy Vector Measurement System
1. Consumption Monitoring System
3. Generation
1. Heat Generation
2. Cool Generation
3. Compressed Air Generation
4. Electricity Generation
5. Renewable Sources
4. Distribution and use
1. Heat and Cool Distribution
2. Lighting
3. Engines and inverters
4. Distribution Pipes 5. Maintenence
1. Machine Ledger
6. General
1. Checklist
2. Vendor List
3. Life Cycle Cost

83
 Energy
Step 6
In collaboration with the Central Energy
Team of Magneti Marelli, guidelines are
created and should be followed for the
proper implementation of management
actions:

The aim of the

document is to give the
guidelines aligned to
the Best Practices &
Knowledge transversally
available in Fiat & MM
Groups to reduce
energy consumption
both for new
equipments and for
existing equipments
16
phamplets

84
Energy
Step 6

All ideas and suggestions and

quick kaizen concerning the
energy sector are transformed
in MP-infos to spread results on
Utilizzo
existing anf future installations.
compressore a
N°5 giri variabili
compressori di
vecchia
generazione
con un basso
rendimento

85
Energy
Step 6
Standard Operating procedure
introduced
Energy
Step 6
MM Energy Book of Standards and
documents followed
Energy
Step 7

Step 7

7. Horizontal
Step 6
expansion
Step 5 6. Standardization

Step 4 5. Countermeasures

Step 3 4. Analysis
Step 2 3. Measurement
(local)
Step 1 2. Investigation

1. Selection of model areas (perspective)

88
 Energy
Step 7
Horizontal Expansion and continuous challenge to reduce

S1
S2
S3
S4
S5
S6
S7
energy conception focusing the 7 types of energy losses

• Horizontal Expansion
• And continuous challenge to reduce energy conception focusing the 7
types of energy losses

89
 Energy
Step 7
Horizontal Expansion and continuous challenge to reduce

S1
S2
S3
S4
S5
S6
S7
energy conception focusing the 7 types of energy losses

Horizontal Expansion
Example

90
 Energy
Step 7
Horizontal Expansion and continuous challenge to reduce

S1
S2
S3
S4
S5
S6
S7
energy conception focusing the 7 types of energy losses

Continuous challenge to reduce energy conception focusing the 7 types of energy losses
Example

91
 Energy
Step 7
Horizontal Expansion and continuous challenge to reduce

S1
S2
S3
S4
S5
S6
S7
energy conception focusing the 7 types of energy losses

Continuous challenge to reduce energy conception focusing the 7 types of energy losses
Example

92
 Energy
Step 7: Long Term Action Plan

Long Term - Action Plan

2012 2016
2012-2016 Expected KPI
Expected KPI

Type of
Vector Project / Activities
losses
Type 6 New high efficiency HV/MV transformer

Type 7 Photovoltaic plant extension

Type 1 2 nd step C635 – all machine with energy saving mode

Electrical Energy
Type 1 Inverter on motors in mist collections system – ext.

Type 7 Increase Renewable Primary Sources

Compressed Air Type 5 Air tank for shot-peening

Heating Type 6 Energy integration with exhausted smoke

93
 THANK YOU

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