Energy Consumption Modeling and Analyses in Automotive Manufacturing Plant

Abstract

Manufacturing plants energy consumption accounts for a large share in world energy usage. Energy consumption modeling and analyses are widely studied to understand how and where the energy is used inside of the plants. However, a systematic energy modeling approach is seldom studied to describe the holistic energy in the plants. Especially using layers of models to share information and guide the next step modeling is rarely studied. In this paper, a manufacturing system temporal and organizational framework was used to guide the systematic energy modeling approach. Various levels of models were established and tested in an automotive manufacturing plant to illustrate how the approach can be implemented. A detail paint spray booth air unit was described to demonstrate how to investigate the most sensitive variables in affecting energy consumption. While considering the current plant metering status, the proposed approach is advanced in information sharing and improvement suggestion determination.