Energy Efficiency Opportunities in Automotive Assembly Process

Energy Efficiency Opportunities 1
ENERGY EFFICIENCY OPPORTUNITIES IN AUTOMOTIVE ASSEMBLY PROCESS
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Energy Efficiency Opportunities 2
ABSTRACT
This review is about the identification of energy efficiency opportunities that exist in automotive
assembly or manufacturing plant. The major research gaps in the previous studies is that these
studies do not illustrates all the energy efficiency opportunities in automotive manufacturing
process and also does not consider only those opportunities that are implementable. The most
intensive energy consuming processes discussed in this review include air compression, metal
forming, ventilation, air conditioning, painting by the use of infrared curing, materials handling,
and welding. After analyzing the production, structure, trends in the automotive industry, and
energy use in various assembly processes, the energy efficiency opportunities are then examined.
The cross-cutting energy efficiency of utility procedures which do not affect the process of
assembly show instant potential for cost-effective savings on energy. Other opportunities
discussed include monitoring and maintenance for compressed air system, improve insulation for
boilers and steam distribution, controlling lighting, high-efficiency belts, variable voltage control
in motors, and recovering cooling water in HVAC.

Energy Efficiency Opportunities 3
1. INTRODUCTION
The opportunities for energy efficiency during the manufacture of automotive are an important
aspect of the sustainability approach of every manufacturing process. This review seeks to
explain the process of automotive assembly and the application of energy in each phase. This
review is then followed by proposed opportunities of energy efficiency which can be
implemented by any vehicle manufacturing plant. The manufacturing process of automotive
entails chassis assembly, engine and parts manufacture, production of the vehicle body, and the
finishes. The automotive assembly company produces various parts by itself, while other parts
are delivered to the assembly plant.
Energy is used in various ways during the process of automotive assembly. Electrical energy is
generally used in the entire plant for various purposes such as air compression, metal forming,
ventilation, air conditioning, painting by the use of infrared curing, materials handling, and
welding. Fuel energy is basically used during source heating, steam application, and curing
ovens of painting lines. One of the most energy-intensive processes during automotive assembly
is metals casting which is applied during engine manufacturing. After the identification of these
energy efficiency opportunities, the evaluation will determine the opportunities that exist to
ensure that manufacturing process is energy efficient.
2. LITERATURE REVIEW
The process of automotive manufacturing entails four primary stages, namely manufacture of
components, production of automotive body, production of chassis, and final assembly. Engines
are cast from iron or aluminum and processed further in engine plants. The vehicle bodies are
normally formed out of sheet steel or with aluminum or plastic parts. The frame or chassis is the

Energy Efficiency Opportunities 4
main structure of the automotive and it forms skeleton on which wheels, transmission,
suspension members, brakes, steering mechanism, axle assemblies, and engine are installed.
Painting and special priming are done to shelter the metallic bodies from corrosion. An
accurately parts and materials flow is substantial to maintain the production of the vehicle in the
assembly plant, to prevent possible disruptions and high inventory cost.
There are various theoretical strategies that automotive manufacturing of assembly plants can
incorporate in their strategies to guarantee improved energy efficiency in their processes. These
measures basically target sections where energy is normally wasted during manufacturing or
assembly processes. Some of these areas include body weld, painting system, lighting, HVAC,
general utilities, motor system, materials handling, and compressed air system. During the
automotive assembly process, there is the use of energy in the whole plant for many applications.
The primary categories of energy needed during the process of assembly include electrical
energy, steam, gas, and air. Energy is used in many user-user categories in the automotive
assembly plant (Hettesheimer, et al., 2018).
Fuels are basically applied during space heating, steam application, and painting lines. The
energy applied during general processes of the plant such as shutting or switching off the
machines when not under operation. The staff members should be educated to change their
behaviour like switching off lights when it is no longer required so as to conserve the energy
within the plant. There is a necessity of changing the management of energy through the
implementation of energy management program in the entire plant so as to promote a successful
and cost-effective way of improving the efficiency of energy (Lazzarin & Noro, 2015). There is
also a necessity of determining the conditions and specifications motor systems used in the plant