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Procedia CIRP 17 (2014) 505 – 510

Variety Management in Manufacturing. Proceedings of the 47th CIRP Conference on Manufacturing

Systems

An Approach for Reducing Energy Consumption in Factories

by Providing Suitable Energy Efficiency Measures
Manuela Krones*, Egon Müller
Professorship Factory Planning and Factory Management, Technische Universität Chemnitz, Erfenschlager Straße 73, 09125 Chemnitz, Germany

* Corresponding author. Tel.: +49-371-531-39416; fax: +49-371-531-839416. E-mail address: manuela.krones@mb.tu-chemnitz.de

Abstract

Energy efficiency has developed into an important objective for industrial enterprises. However, there is still a need for systematic approaches
to reduce energy consumption in factories. Existing methods focus on the optimization of manufacturing processes and lack upon considering
the entire factory system. Additionally, they are based on a detailed quantitative analysis of processes and thus, they need a high effort during
the phase of data acquisition. Therefore, an approach for reducing energy consumption by providing energy efficiency measures to factory
planning participants was developed in order to overcome these barriers. The general approach is described in this paper and supported with a
use case that demonstrates the required information and possible outcomes in terms of energy efficiency information. Main advantages of this
approach are reducing the effort to acquire energy data and the possibility to consider the factory system holistically.
© 2014 Elsevier B.V. This is an open access article under the CC BY-NC-ND license
© 2014 The Authors. Published by Elsevier B.V.
(http://creativecommons.org/licenses/by-nc-nd/3.0/).
Selection and peer-review under responsibility of the International Scientific Committee of “The 47th CIRP Conference on Manufacturing
Selectioninand
Systems” thepeer-review
person of theunder responsibility
Conference of the International
Chair Professor Scientific Committee of “The 47th CIRP Conference on
Hoda ElMaraghy.
Manufacturing Systems” in the person of the Conference Chair Professor Hoda ElMaraghy”
Keywords: energy efficiency; energy management; factory planning; factory management; energy efficiency measure

1. Introduction Despite this situation, the implementation of energy

The importance of energy efficiency as an objective for
industrial enterprises increases due to ecological, political and
economic reasons. Considering the ecological perspective, the
International Energy Agency identified energy efficiency as
most important driver to reduce global greenhouse gas
emissions [1]. Political conditions are fixed upon both
international and national levels. For example, the European
Union drafted a long-term strategy in the “Energy Roadmap
2050”, which includes, among other things, an 80-95 %
reduction of greenhouse gas emissions until 2050 [2]. From
an economic point of view, industrial enterprises have an
incentive to reduce their energy consumption because of
increasing energy prices, such as the European average prices
for gas in industry, which rose by approximately 34 % during
the last four years [3].
efficiency measures has not met the expectations yet. The
reasons for the deficits in realizing energy efficiency include
lack of time, lacking transparency on energy consumption,
lacking capital for investments and divided responsibilities
within a company [4].
Different tools and methods have been developed in recent
years to support the systematic analysis and optimization of
industrial enterprises for reducing their energy consumption.
However, the existing methods mainly focus on
manufacturing processes and systems. Although these are
important aspects of the energy-efficient factory, considering
the interrelationships between products, processes and
resources in the factory system is essential for a holistic
integration of energy efficiency in the enterprise.
Another barrier in implementing methods is the high effort
for data acquisition. Therefore, an approach to reduce energy
consumption within factory systems was developed that

2212-8271 © 2014 Elsevier B.V. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/3.0/).
Selection and peer-review under responsibility of the International Scientific Committee of “The 47th CIRP Conference on Manufacturing Systems”
in the person of the Conference Chair Professor Hoda ElMaraghy”
doi:10.1016/j.procir.2014.01.045
506 Manuela Krones and Egon Müller / Procedia CIRP 17 (2014) 505 – 510

provides energy efficiency measures to factory planning energy recovery and direct use of losses for heating [8].
participants based on qualitative data [5]. Further examples can be found in [5].
The remainder of the paper is organized as follows: An Energy efficiency methods describe a systematic approach
overview of the state of the art of energy efficiency-oriented on the identification and realization of energy efficiency
factory planning is described in section 2. The overall concept improvement opportunities. There are varieties of energy
for the methodical approach is presented in section 3. A efficiency methods available in scientific literature, from
detailed use case describes the implementation of the which only a selection is presented in the following. The
approach in section 4. Section 5 summarizes the results and majority of energy efficiency methods focuses on
gives an outlook on future research work. manufacturing processes and identifies measures based on a
detailed quantitative analysis of the underlying processes,
2. State-of-the-art whereof mainly manufacturing processes are considered (e.g.
[9, 10]). Some contributions describe the implementation of
In general, existing tools for considering energy efficiency analyses with regard to the requirements of a specific sector
of manufacturing systems can be divided into assessment, [11]. Other publications expand the approaches in terms of
monitoring and inventory tools on the one hand while other objectives (e.g. resources, waste) and to a wider system
engineering, design and improvement tools on the other [6]. definition (e.g. factory level) [12, 13]. There are also methods
The following discussion is focused on the second group, that do not require a quantitative analysis but lack to provide
since the aim is to reduce energy consumption in factory methodical support for the deduction of appropriate energy
systems. efficiency measures. The main focus of these methods is to
The existing tools to support energy efficiency-oriented create transparency within the process (e.g. [14]).
factory planning and management can be divided into energy In general, the existing energy efficiency methods can be
efficiency guidelines, principles and methods [5]. Table 1 described by the general scheme to define a system, analyze
provides an overview on these tools, which are described in the processes within the system by means of energy
detail in the following. measurements, prioritize sub-systems and deduce energy
efficiency measures. By using the measurement results, the
Table 1. Overview on existing types of tools for energy-efficient production. expected savings of energy efficiency measures can be
Description Example(s) assessed quantitatively.
However, this state-of-the-art approach requires high
US Department of Energy –
Energy Collection of energy efforts during the analyzing phase in order to acquire the
Energy Efficiency &
efficiency efficiency measures in
Renewable Energy: Guide to relevant data. Another barrier lies in the necessity of expert
guidelines specific sectors or fields knowledge for the deduction and description of energy
Energy-Efficient Lighting [7]
efficiency measures since the existing methods do not
x substitute energy sources describe this step detailed enough to enable practitioners to
Energy Small number of general x increase efficiency of transfer it to another application on their own.
efficiency approaches for energy equipment Thus, there is need for research for developing an approach
principles efficiency
x energy recovery to systematically identify suitable energy efficiency measures
(selected according to [8]) for a defined project task without the high effort of acquiring
Systematic approaches to energy consumption data. The deduction of measures should
Energy Energy metering and be transparent in order to make the approach understandable
identify and realize energy
efficiency assessment of manufacturing
methods
efficiency improvement
processes
and manageable.
opportunities
3. Methodical Approach
Guidelines provide an overview on energy efficiency
The two most important requirements for the methodical
measures within a specific industrial sector or a specific field
approach are the systematic procedure and the reduction of
of application (e.g. lighting). The guidelines are mainly
effort for system analysis. The systematic procedure needs to
published by independent institutions or governmental
ensure that information to factory planning participants is
organizations (e.g. [7]). By providing information close to
provided in a structured way (compared to energy efficiency
application and including examples of realization within
guidelines, where there is no guidance for practitioners to find
enterprises, the guidelines are suitable for practitioners.
the information that is relevant for their specific situation).
However, finding the information that is relevant to a specific
The reduction of effort for system analysis increases the
use case requires lots of effort and time.
applicability of the methodical approach since high effort for
Energy efficiency principles contain a collection of a small
data acquisition without the possibility to forecast the results
number of general approaches to increase energy efficiency.
in energy savings is a high barrier for industrial application.
They are identified by generalizing energy efficiency
Based on these requirements, a general concept has been
measures and are mainly published by research institutions or
developed to systematically guide a factory planning
consultancies. One example is distinguishing between
participant from his or her project task to appropriate energy
substitution of energy sources, reduction of energy demand,
efficiency measures. The goal is to provide suitable energy
increase efficiency of equipment, reduction of process losses,
efficiency approaches in order to increase the efficiency of
 Manuela Krones and Egon Müller / Procedia CIRP 17 (2014) 505 – 510
information gathering. The approach consists of four major
steps, which are explained in the following (Figure 1).
The starting point for the approach is the definition of the
project task or planning situation by the factory planning
participant (user input). The most important parameters to
describe the task are object level, system process, part of the
energy chain, energy form, planning case and user’s role.
According to their background, the first four parameters are
defined as technical parameters and the last two as
organizational parameters.
The object level describes the level of abstraction of the
considered system (e.g. factory, building, plant area, single
machine). The system process defines the process of the
enterprise to which the considered system belongs to (e.g.
assembly, logistics). The part of the energy chain describes
whether the system performs energy generation, conversion,
distribution, storage or use, since factories increasingly
integrate several of these functions [15]. The energy form
defines the types of resources that are used within the
considered system (e.g. electricity, water). The planning case
comprises the extent to which changes are possible in the
system; planning a new system has the highest degrees of
freedom, whereas operating the existing system equals the
lowest degree of freedom. Finally, the user’s role defines the
perspective of the user (e.g. factory planner, worker).
When applying the method, not all of these parameters
need to be specified. The user can choose which parameters to
specify; however, if the number of specified parameters is too
small, the user may receive too unspecific results and needs to
repeat the approach with changes in the input.
User input
1. Analysis of the situation
2. Identification of
influential opportunities
3. Deduction of measures
Energy efficiency
measures
4. Identification of
realization information
Energy efficiency
realization information
User satisfied?
No
Yes
Suitable energy efficiency
measures and information
towards their realization
Figure 1. Overall concept for methodical approach to systematically identify
energy efficiency measures
507
As a first step, a model of the considered system is created
in order to identify improvement opportunities (1. analysis of
the situation). The required energy form defines the objective
as starting point of the analysis (e.g. consumption of
electricity). The model of the considered system consists of
two parts: The general model is developed depending on the
parameter object level, whereas the subordinate system-
specific model refers to the parameter system process. The
general model contains indicators that can be influenced on
the object level. The detailed physical parameters that affect
these indicators are specified in the system-specific model.
Afterwards, the organizational parameters of the user input
are analyzed in order to identify improvement opportunities
for the specific project task (2. identification of influential
opportunities). The general possibilities, i.e. the technical
improvement opportunities, are limited to the opportunities
within the given organizational restrictions. This means that
the parameters identified within the general and system-
specific model during the situation analysis are examined in
more detail. For each of them, it needs to be checked whether
the parameter can be influenced in this situation (control
factors) or not (noise factors). The control factors that are
determined in this step are also referred to as influential
opportunities.
The information of the influential opportunities is used in
order to search for suitable energy efficiency measures in a
database (3. deduction of measures). For this step, the energy
efficiency measures need to be structured according to
different criteria in order to support the matching between
influential opportunities and energy efficiency measures. The
existing energy efficiency guidelines and energy efficiency
principles (see section 2) need to be integrated in the
collection of energy efficiency measures.
In the next step, useful information on the realization of
energy efficiency measures is identified (4. identification of
realization information). A set of categories was developed to
structure this information:
x Basic information: Which basics are relevant to know?
x Relevance: Why is energy efficiency important in this
field?
Changes in x External requirements and information: Which
user input
requirements do exist?
x Principles: How does this measure work?
x Benefit: What is the benefit in realizing this measure?
x Industrial examples: Who applies this measure
successfully?
The content provided within these categories is tailored to
the user’s situation by using all of the input parameters. For
example, the plant engineer receives more information on the
functionality of a measure whereas the manager receives more
information regarding the economic efficiency.
At this point, the user has the possibility to change the
inputs if the results are not yet satisfying. Otherwise, the user
receives suitable energy efficiency measures and information
towards the realization.
508 Manuela Krones and Egon Müller / Procedia CIRP 17 (2014) 505 – 510

4. Use Case In the next step, the technical parameters are used to create
a model of the energy consumption in the considered system
In the following, a fictive use case for the application of (Figure 2). As described in section 3, the starting point for the
the methodical approach is demonstrated. The necessary analysis is the required energy form. In this use case,
information in terms of energy efficiency measures and electricity is the only one, so the objective is to reduce the
realization information is provided by a small prototype electrical work of the plate conveyor. The next step is to
which was created using a literature review. It includes 35 create the general and the system-specific model. The general
energy efficiency measures and 80 blocks of realization model depends on the object level “machine”. Thus, the
information. The case is on the object level of a single electrical work for the system is divided into the different
machine and analyzes a plate conveyor in the final assembly condition states of the machine, i.e. processing, ready-to-
of an automotive assembly line. operate and stand-by. The processing state means that the
The initial situation of this use case is a plate conveyor that system operates, i.e. transports cars. The ready-to-operate
is operated within an automotive final assembly line. It state means that the conveyor is ready to transport cars, which
transports the finished cars from the wheel assembly to and means that the conveyor is moving without any car on it
through the quality assurance at the end of the assembly. For (system waits). The stand-by state indicates that the system is
this task, the conveyor needs electricity as energy form. The not in movement but not totally switched off. This means,
project task is to redesign the plate conveyor as part of a control panels and similar facilities are switched on and it
rationalization measure. The logistics planner wants to know only takes a short time to move the system back into
about energy efficiency measures that can be realized in this operation.
situation with a moderate budget. Since the work for processing refers to mechanical work
The starting point for the approach is the user input for this rather than electrical work, a conversion of electrical energy
specific project task, which is shown in Table 2. to mechanical energy is needed in this system. Therefore,
conversion losses are part of the objective electrical work and
Table 2. Use case machine – user input for methodical approach need to be considered in the general model.
Parameter Specification It should be noted that this general model can be used for
Object level Machine any considered system on the object level “machine”, i.e. it is
System process – core process Assembly only based on the input parameter “object level” but does not
depend on the system process. The system process, however,
System process – support process Logistics
is included in the system-specific model, i.e. in the physical
Part of the energy chain Energy use parameters that influence the parameters within the general
Energy form Electricity model.
Planning case Retrofit Using the organizational parameters, the basic influential
User’s role Logistics planner opportunities are now divided into control factors and noise
factors – depending on whether they can be changed within
the given restrictions. In Figure 2, the control factors in this
use case are formatted bold.
Objective

Electrical
work

Work for Work for ready- Work for Losses

General Model

processing to-operate stand-by work

Operating Processing Waiting Ready-to- Stand-by Stand-by Operating Losses

time power time operate power time power time power
System-specific

Mass Mass Conveyor Mass Conveyor Drive

Model

goods conveyor velocity conveyor velocity efficiency

Friction Power peripheral Friction Power peripheral
coefficient components coefficient components

Figure 2. Use case machine – model of the energy consumption for identifying influential opportunities
 Manuela Krones and Egon Müller / Procedia CIRP 17 (2014) 505 – 510 509

Energy efficiency measure

…
Use energy-efficient motors
Basic information Which basics are relevant to know? Principles How does this measure work?
• Motor efficiency = ratio between offered mechanical power and • Motor efficiency improved by increased copper diameter, improved
supplied electrical power [16]. winding technology and improved air routing inside [16]
• Losses in a motor [16]:
• Fixed losses (iron losses, friction losses)
• Variable losses (copper losses in stator and rotor) Benefit What is the benefit in realizing this measure?
Relevance Why is energy efficiency important in this field? • Investment in energy-efficient motors usually pays off after 1 to 3
• Up to 95 % of the life cycle costs of a motor are caused by energy years [17]
consumption [17] • What needs to be considered when evaluating a replacement [21]:
• Systems driven with electric motors cause approximately 70 % of • Investment cost
industrial energy consumption [16] • Motor run-time
• Planned replacements due to maintenance
External requirements and information Which requirements do exist?
• IEC 60034-30 specifies energy-efficiency classes, which need to be
provided by the motor producer (motor plate and documentation)
[18]: Industrial examples Who applies this measure successfully?
• IE 1 Standard Efficiency
• Example handling of baggage in an airport [22]:
• IE 2 High Efficiency
• Starting point: use of standard motors
• IE 3 Premium Efficiency
• Measure: replacement by energy-efficient motors (IE 2)
• IE 4 Super Premium Efficiency
• Reduced energy consumption of 61.900 kWh/year
• EU requirements: IE 2 motors as from June 2011, IE 3 motors as
• Reduced energy costs of 6.190 €/year
from January 2015 [19]
• Pay-off time approximately 2.2 years
• USA requirements: IE 3 motors as from December 2010 [20]
Figure 3. Use case machine – detailed description of realization information for measure 5 “Use energy-efficient motors”

In the following, each of the influential opportunities is Combining the general and the system-specific model, the
described and the assignment to control or noise factors is control factors are waiting time, stand-by time, stand-by
explained. It should be noted that the differentiation between power, power of peripheral components and drive efficiency.
control and noise factors is performed on the last stage of Using this information of control factors, a database is
parameters, i.e. when there is no further refinement of a searched for relevant energy efficiency measures. The result is
parameter. shown in Table 3.
The general model contains the parameters operating time,
waiting time, stand-by time and stand-by power. The planning Table 3. Use case machine – identified energy efficiency measures (selection)
case in this use case is a retrofit, i.e. no changes in the No. Energy efficiency measure
Directly influenced
logistics process are intended. This means that the logistics parameter
planner has no influence on the operating time. However, the 1 Adjust nominal power of motors Drive efficiency ↑
logistics planner may influence the share of waiting and Enable switching conveyor sections in
stand-by times by changing the system control. The stand-by 2 Waiting time ↓
stand-by mode when they are not in use
power is influenced by the definition of the components that
3 Increase transmission efficiency Drive efficiency ↑
are operated in stand-by mode. Therefore, the control factors
in the general model are waiting time, stand-by time and Reduce energy consumption of control Power peripheral
4
system components ↓
stand-by power.
The system-specific model comprises the parameters mass 5 Use energy-efficient motors Drive efficiency ↑
of goods, mass of conveyor, friction coefficient, conveyor Use synchronous motors instead of
6 Drive efficiency ↑
velocity, power of peripheral components and drive asynchronous motors
efficiency. As already mentioned, the logistics planner does
not intend to change the process, i.e. the mass of the goods Finally, the user receives information on the energy
and the conveyor velocity cannot be influenced. The mass of efficiency measures which enables him or her to integrate the
the conveyor and the friction coefficient depends on the measures in the planning project. An example of realization
material and the construction of the plate conveyor. Changing information of measure 5 “Use energy-efficient engines” is
these components would need a high effort in time and cost, shown in Figure 3.
which is not possible within this retrofit. The power of As described in section 3, the information is divided into
peripheral components depends on the control of the plate six parts. The content within the categories is adjusted
conveyor which can be changed in a small project. The drive according to the user’s role. For example, the logistics planner
efficiency depends on the choice of motors and gearboxes, does not need to know the details of the principles, i.e. how
which can be changed as part of the retrofit. motors are constructed and developed to reach a higher
efficiency. Therefore, the part “principles” is very short in this
510 Manuela Krones and Egon Müller / Procedia CIRP 17 (2014) 505 – 510
case. Furthermore, the content in the realization information
can be changed dynamically, i.e. the users themselves can add
relevant information, such as their own experiences in
implementing the measure.
It should be noted that the primary goal of the approach is
to reduce energy consumption. The effectiveness in terms of
costs and benefits needs to be estimated by the user with the
help of the realization information (especially categories
“Benefit” and “Industrial examples”).
5. Summary and Outlook
In this paper, it has been shown that there is a research
need in developing an approach for the systematic
identification of energy efficiency measures without the high
efforts of acquiring energy consumption data. The developed
general approach is based on qualitative input information and
enables the user to identify energy efficiency measures that
are appropriate in his or her planning situation. The use case
demonstrated the developed categories for structuring both the
planning situation and the energy efficiency information.
Further research will contain expanding the existing
approach both in terms of a higher abstract level of the
considered system (e.g. factory buildings) and in terms of the
considered objectives (e.g. greenhouse gas emissions).
Furthermore, additional information needs to be integrated
into the realization information (e.g. correlation between
measures).
Acknowledgements
The Cluster of Excellence “Energy-Efficient Product and
Process Innovation in Production Engineering” (eniPROD®)
is funded by the European Union (European Regional
Development Fund) and the Free State of Saxony.
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