Methods-Energy Measurement – An approach for sustainable energy planning of manufacturing technologies

Abstract Given the self-declared energy and environmental protection objectives of many car manufacturers responsible companies must use energy-efficient production technologies. The running costs of production sites are a decisive factor in the overhead of automotive production. Therefore, it is important for many operators to reduce those costs in a sustainable way. For this purpose, they attempt to reduce both the energy consumption costs and CO2 emissions of production systems. However, most components of the energy costs are determined during the very early phases of the product creation process. To achieve an estimation of the energy consumption in this early planning stage, a new suitable forecasting method is required. Therefore, this paper presents an approach for determining the prospective energy consumption by using Methods-Energy Measurement combined with defined energy reference cycles for manufacturing technologies. With this approach, key performance indicators are defined, and the production technologies are divided into basic energy consumers. The average energy values will be determined empirically by using the defined energy reference cycles. With these data, the energy demands for different scenarios are calculated. Thereby, it is possible to estimate the potential energy consumption of complex manufacturing cells. The designed method is validated within a case study of a modern automotive body shop. In summary, the approach contributes to identify and realize sustainable solutions in advance and thus increase the profitability of a factory.