Quantifying Energy Savings from Lean Manufacturing Productivity Increases

Abstract

A number of energy efficiency programs seek a reduction in the energy intensity of manufacturing processes. However, promoting energy efficiency through productivity improvements is not a widely accepted practice. As such, accepted methods used to calculate energy savings from productivity improvements are not prevalent. This paper will first review several existing energy efficiency programs that promote manufacturing productivity increases: Northeast Utilities’ PRIME Program and the DOE Industrial Assessment Centers. In conjunction, this paper will review the methods used to quantify energy savings for each program. Additionally, the relationship between productivity improvements (specifically Lean Manufacturing techniques) and energy use will be explored in detail. Lean techniques reduce energy use in several ways, which will also be discussed. This paper will apply the categorization of energy use reduction types and equipment types to develop new methods for calculating energy savings from productivity improvements.