DOE Plant-Wide Energy Assessment Results Related to the U.S. Automotive Industry 2006-01-0594

Forty-nine plant-wide energy efficiency assessments have been undertaken under sponsorship of the U.S. Department of Energy's Industrial Technologies Program. Plant-wide assessments are comprehensive, systematic investigations of plant energy efficiency, including plant utility systems and process operations. Assessments in industrial facilities have highlighted opportunities for implementing best practices in industrial energy management, including the adoption of new, energy-efficient technologies and process and equipment improvements. Total annual savings opportunities of $201 million have been identified from the 40 completed assessments. Many of the participating industrial plants have implemented efficiency-improvement projects and already have realized total cost savings of more than $81 million annually. This paper provides an overview of the assessment efforts undertaken and presents a summary of the major energy and cost savings identified to date. The paper also discusses specific results from assessments conducted at four plants in the automotive manufacturing operations and supporting industries. These particular assessments were conducted at facilities that produce engine castings, plastic films used for glass laminates, forged components, and at a body spray painting plant.