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
Currently, there exist various energy efficiency technologies which are applied in the
automotive industry to reduce the cost incurred in production. However, the automotive
manufacturing industries still experience numerous challenges concerning feasible energy
efficiency opportunities in managing greenhouse gas emissions, energy consumption, and
production costs. This review seeks to identify a suitable energy efficiency opportunity that
exists in the automotive assembly or manufacturing plant. The most intensive energy consuming
processes discussed in this review include air compression, metal forming, and 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
essential aspect of the sustainability approach of every manufacturing process. This review seeks
to review the Energy efficiency in automotive manufacturing systems. This review is then
followed by proposed opportunities for 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 multiple 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, and ventilation, air conditioning, painting by the use of infrared
curing, materials handling, and welding. Fuel energy is 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 the manufacturing process is energy efficient.
This plan will discuss some of the existing literature on the energy efficiency
opportunities in the automotive assembly process, followed by a theoretical basis of the work to
be undertaken. Thereafter, it will provide an experimental set up for the design and explain the
expected outcomes. A grant chart will be generated for the anticipated timelines for completion
of the project.

Energy Efficiency Opportunities 4
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 typically formed out of sheet steel or with aluminum or plastic parts. The
frame or chassis is the 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 approach to guarantee improved energy efficiency in their processes.
These measures target sections where energy is typically 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 (Hettesheimer
et al., 2018).
Fuels are applied during space heating, steam application, and painting lines. The energy
used 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 behavior like
switching off lights when it is no longer required 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 to promote a successful and cost-effective way of
improving the efficiency of power (Lazzarin & Noro, 2015). There is also a necessity of