Exploring Energy Efficiency in Vehicle Manufacturing Processes

This report proposes energy efficiency opportunities within vehicle manufacturing processes, focusing on engine and parts manufacture, vehicle body production, chassis construction, painting, and assembly. It highlights energy-intensive processes and suggests strategies for reduction, such as upgrading motor systems, optimizing compressed air systems, improving lighting, and enhancing HVAC and painting systems. The study emphasizes the importance of employee training and the implementation of formal energy management systems for continuous improvement. Data was gathered from field setups in assembly plants, including major automotive companies, and analyzed to identify practical energy-saving measures. The report advocates for the adoption of high-efficiency technologies like inverter welding and multi-welding units to further minimize energy consumption and enhance overall efficiency in vehicle manufacturing.

Energy Efficiency 1
PROPOSED ENERGY EFFICIENCY OPPORTUNITIES IN VEHICLE MANUFACTURING
PROCESSES
A Proposal Paper on Energy By
Student’s Name
Name of the Professor
Institutional Affiliation
City/State
Year/Month/Day

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EXECUTIVE SUMMARY
In Australia, the motor vehicle industry consumes approximately %3.6 billion on energy
yearly. In the assembly plant, the expenditure of energy is a relatively low-cost factor in the
overall process of production. Nevertheless, this sector faces an increasingly competitive
environment, hence the improvement in energy efficiency can ensure a way of reducing the costs
without adversely affecting the quality and yield of the vehicle production. The reduction of
energy costs reduces the unpredictability involved with the variations of energy prices in the
current marketplace, which could adversely impact the earnings that are predictable. The
technologies of energy efficiency normally include extra benefits and increased the productivity
of the assembly plant.
The vehicle body is made up of sheet steel, however, there has been a trend towards
moving to aluminium and plastic parts bodies. In some parts of the vehicle body, reinforced
plastic, fibreglass, and aluminium are used due to their special properties. Handling plastic
components normally cost less and need less duration to develop compared to the components of
steel, making the plastic components very attractive to the vehicle manufacturers. The chassis is
the major structure of the vehicle and is made of pressed-steel frame in the majority of designs.
The parts such as suspension member, brakes, steering mechanism, transmission, axle
assemblies, wheels, and engine are mounted on the chassis. Special painting and priming are
used to protect the vehicle bodies from corrosion.

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INTRODUCTION
This energy efficiency opportunity is a significant component of the environmental
strategy of any assembly plant. This proposal paper seeks to evaluate the process of motor
vehicle assembly and the energy use in every stage. This is then followed by proposal on the
energy efficiency opportunities for the assembly plant. The process of vehicle manufacturing
includes engine and parts manufacture, vehicle body production, chassis, painting, and assembly.
The vehicle assembly plant generates numerous components by itself, while other components
are supplied to the company. Metal casting used in the manufacture of engines is a production
process that is very energy intensive. This can be reduced through recycling of these parts by the
metal casting industry so as to ensure energy efficiency in their materials used in their
manufacture.
Energy is applied in numerous different ways during the vehicle assembly process. Fuels
are majorly used during curing ovens of painting lines, steam application, and source heating.
Electricity is used in the entire facility for numerous purposes such as welding, materials
handling, painting by use of infrared curing or fans, air conditioning, ventilation, lighting, metal
forming, and compressed air (Abraham, 2017).
LITERATURE REVIEW
The assembly of motor vehicles uses energy in the entire plants for numerous end-users.
The major types of energies required during assembly process include compressed air, gas,
steam, and electricity. Energy is applied to diverse categories of user-users in the facilities of
vehicle assembly. Fuels are majorly used during curing of ovens for painting lines, steam
applications, and space heating.

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General Utilities
These are energy used during the general operations of the facility such as in lighting or shutting
down machines when not using. There is a need for changing the behaviour of staff such as
switching off lights when not using so as to save energy. There is need of changing how energy
is managed through incorporating an energy management program that is organization-wide so
as to ensure cost-effective and successful was of improving energy efficiency. There is need of
the evaluating the specifications and conditions of motor systems that are used in the facility in
cooling, refrigeration compressed air, and air conditioning (Agugliaro, 2011).
Motor Systems
These motor systems should be repaired and upgraded to ensure optimum performance and
enable improvements in energy efficiency. This efficiency can be considered by taking the
systems approach which strives to optimize the efficiency of the whole of the motor system such
as driven systems like compressors, fans, and pumps, or in motors and drives. Constant
maintenance of these motor systems ensure that there is unexpected downtime of the motors,
these measures include lubrication, alignment, motor ventilation, load consideration, and voltage
imbalance reduction (Anderson, 2003).
Compressed Air Systems
This the most expensive energy form used in the facility due to its poor efficiency. Insufficient
maintenance of the compressed air systems calm reduce the efficiency of compression and
increase pressure variability or air leakage, and result to increased temperatures of operation,
excessive contamination, and poor control of moisture (Arthur, 2014).

Energy Efficiency 5
Lighting
Lighting is used in the provision of general ambient light in the whole of the office spaces and
manufacturing storage or in the provision of task lighting in specific regions. The sources of
high-intensity discharge are used for storage and manufacturing sections such as mercury vapour
lamps, high-pressure sodium, and metal halide. Lighting regulations can be performed by
shutting off lights during non-operation hours by the use of automatic control like occupancy
sensors (Backus, 2009).
Heating, Ventilation, and Air Conditioning
The HVAC involved air conditioning, ventilation, and heating systems and it involves a
significant quantity of energy. Companies are currently improving their cooling and ventilation
systems which respond to the present conditions within the facility, cooling output according to
the demand or better matching ventilation. Building shell can also be incorporated to serve as
insulation from cold or hot weather conditions. Modification of the fans can also save energy by
regulating the flow of air and running at the design velocity (Beer, 2013).
Painting System
These are the major energy consuming section in the automobile facility and plants. The energy
is used in conditioning air for drying and painting steps and also for treatment of emission and
drying process. Energy efficiency can be improved in the painting systems through maintenance
and management of painting lines, recovery of existing paint lines, and optimization of heat
distribution. This can be attained by avoiding over-thinning water-born or solvent coatings
through the addition of too much solvent, avoiding too large volumes of air in the air to fuel

Energy Efficiency 6
ration, and also maintaining the ventilation, humidity, and temperature to be within appropriate
range for effective operation (Bunse, 2011).
High-Efficiency Inverter/Welding Technology
In high-efficiency inverter and welding, there is shut down of power during cooling fans and
system idling, avoiding continuous consumptions of electricity. There will be improved power
factor and provision of better electrical efficiency. Welding power of high efficiency provides a
wider range of power compared to the traditional technologies (Research, 2009). Some
companies such as Lincoln Electric for position welding and track welding have the
implementation of multi-welding units which can permit a number of diverse welding machines
to be operated by a single source of power. This will need no downtime for switching between
their building fabrication and bridge, a higher rate of deposition, reduced cleanup time, and use
of less power (Campana, 2017).
RESEARCH OBJECTIVE
The main objective of this research is to evaluate the energy efficiency opportunities in
the vehicle manufacturing process. These vehicle manufacturing processes majorly include
engine and parts manufacture, vehicle body production, chassis, painting, and assembly. The
researchers seek to evaluate these processes and determine the opportunities for energy
efficiency so as to reduce the overall energy required during the manufacturing process. The
opportunities realized can be implemented in the numerous assembly plants (Galitsky, 2010).
RESEARCH QUESTION
 What are some of the processes involved in the vehicle manufacturing process?
 Which of these vehicle manufacturing processes are energy intensive?
 How can the energy usage in these processes be reduced?

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 Which are some of the proposed energy efficiency opportunities in the vehicle
manufacturing process? (Seog-Chan, 2016)
THEORETICAL CONTENT/ METHODOLOGY
There are numerous theoretical approaches that vehicle assembly or manufacturing
facilities can implement their processes to ensure energy efficiency in their operations. There
approaches majorly target areas where energy is generally wasted while carrying out various
activities in the assembly or manufacturing processes (Sutherland, 2012). Some of these areas
include materials handling and tools, HVAC, lighting, compressed air system, motors system,
general utilities, painting system, and body weld. There is need of establishment of formal
management systems and structures for managing energy that aims at continuous improvement.
These strategies are expected to assist the facility to manage energy use and implement energy
efficiency measures (Ganapathy, 2009).
Energy straining programs can also be incorporated to train the employees at all levels
about energy efficiency practices into their daily work routines and also the objective of the plant
for energy efficiency improvement. The will ensure that all the employees their responsibilities
towards ensuring energy efficiency in their normal activities (Muthulingam, 2014). Energy
efficiency can be improved in the painting systems through maintenance and management of
painting lines, recovery of existing paint lines, and optimization of heat distribution. This can be
attained by avoiding over-thinning water-born or solvent coatings through the addition of too
much solvent. These motor systems should be repaired and upgraded to ensure optimum
performance and enable improvements in energy efficiency (Green, 2010).

Energy Efficiency 8
This efficiency can be considered by taking the systems approach which strives to
optimize the efficiency of the whole of the motor system such as driven systems like
compressors, fans, and pumps, or in motors and drives. The motor management plan can also
help the facility realize long-term motor system energy savings and will ensure that failures of
the motor are handled cost effective and quick manner (Takahashi, 2011). Assembly facilities
should also consider the implementation of multi-welding units which can permit a number of
diverse welding machines to be operated by a single source of power. This will need no
downtime for switching between their building fabrication and bridge, a higher rate of
deposition, reduced cleanup time, and use of less power (Henriques, 2013).
Maintenance and monitoring can also lower the compression efficiency and increase
pressure variability or air leakage, and result in increased excessive contamination, poor moisture
control, and increased operating temperature. This will involves fans inspection, specific
pressure regulators, and unblocking pipeline filters (Herrmann, 2011).
EXPERIMENTAL SETUP
This research on the energy efficiency opportunities in vehicle assembly and
manufacturing processes focuses on field setup in gathering data and evaluation of these data
acquired from the numerous assembly plants and facilities. The big three automotive companies
whose case studies can be used for the purposes of data acquisition include Daimler Chrysler
Corporation, Ford Motor Company, and General Motors Corporation. The quantities of
qualitative research borders on knowledge, skills as well as capabilities of researchers. The
results may be personal because of the assumption that the outcomes are basically coming from
the researcher's judgments and personal interpretations. Indeed, this judgment is more

Energy Efficiency 9
appropriate for a small sample as used in this research. It is however not reliable for results of
qualitative research to reflect the opinions of a wider population (Islam, 2011).
The respondents would be asked the questions regarding the energy efficiency
opportunities that have been implemented or that can be implemented within the assembly
facility to ensure efficiency in energy usage. Some of the questions include; what are some of the
processes involved in the vehicle manufacturing process? Which of these vehicle manufacturing
processes is energy intensive? How can the energy usage in these processes be reduced? Which
are some of the energy efficiency opportunities in the vehicle manufacturing process?
Respondents will also be allowed to make remarks on matters not enclosed by exact questions in
the survey (Lee, 2010).
The participants of this research represent the total member of people by way of a
complete headcount and everything the research seeks to uncover. The survey will be
administered to a total of 50 participants. These participants were employees chosen at random
in the numerous vehicle assembly plants in the country such as Ford Australia, General Motors,
Toyota Australia, and Denning manufacturing. The major problems that are likely to be
encountered by the research team during the field setup include geographical differences and
also language barriers. Some of these companies are located in the different geographical area
making it difficult to reach and carry out the research (Melamed, 2009).

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POTENTIAL RESULTS, OUTCOME AND RELEVANCE
The table below shows the relevance of each hypothesis in answering the research questions:
Research Question Relevant Hypotheses
Q1 Are energy wasted during the vehicle
manufacturing process?
HI Huge amount of energy is wasted
during the vehicle manufacturing
process.
Q1 What are some of the processes involved
in the vehicle manufacturing process?
H2 The vehicle manufacturing process
include engine and parts
manufacture, vehicle body
production, chassis, painting, and
assembly.
Q2 Which of these vehicle manufacturing
processes is energy intensive?
H3 Energy intensive processes include
materials handling and tools, HVAC,
lighting, compressed air system,
motors system, general utilities,
painting system, and body weld
Q3 How can the energy usage in these
processes be reduced?
H4 Energy training programs for
employees, formal management
systems and structures for managing
energy, Lighting regulations, high
efficiency welding technology, and
motor management plan.
Q4 Which are some of the energy efficiency
opportunities in the vehicle
manufacturing process?
H5 Formal management systems and
structures for managing energy and
Energy training programs for
employees.
Table 1: Summary of Relevance between Hypotheses and Research Question
From the data attained from the research on the energy efficiency opportunities in the vehicle
manufacturing processes above some of the energy-saving opportunities that will lead to extreme
energy saving opportunities include establishment of formal management systems and structures
for managing energy that aim at continuous improvement, incorporation of Energy straining
programs to train the employees at all levels about energy efficiency practices, and Lighting
regulations can be performed through shutting off lights during non-operation hours by the use of
automatic control like occupancy sensors (Mulder, 2017).

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PROJECT PLANNING
Project Phase
Number
Project Phase Estimated Duration
(Months)
Start-End Date (By
week number)
1 Project Preparation 2 1 -3rd Month
2 Project Execution 5 4rd -9th Month
3 Analysis and Validation 8 10th -18th Month
4 Final Report Writing 4 19th-23rd Month
Total 23 months 23rd Month
Figure 1: Engineering Graduate Project Phases
Figure 2: Proposed Project Schedule, Activities and Gantt chart
CONCLUSION
The main objective of this research is to evaluate the energy efficiency opportunities in
the vehicle manufacturing process. These vehicle manufacturing processes majorly include
engine and parts manufacture, vehicle body production, chassis, painting, and assembly. The

Energy Efficiency 12
major energy consumptions in assembly facility include materials handling and tools, HVAC,
lighting, compressed air system, motors system, general utilities, painting system, and body
weld. A total of 50 participants were involved in this research and majority of them were
employees chosen at random in the numerous vehicle assembly plants in the country such as
Ford Australia, General Motors, Toyota Australia, and Denning manufacturing. Energy training
programs are one of the energy efficiency opportunities that be incorporated in any automobile
plants to train the employees at all levels about energy efficiency practices into their daily work
routines and also the objective of the plant for energy efficiency improvement.

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