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New Energy Management Case Studies Showcase Savings for U.S., Canadian Facilities

Case studies feature ISO 50001 use and resulting energy cost savings with energy management

Tuesday, September 15, 2015

New Energy Management Case Studies Showcase Savings for U.S., Canadian Facilities

Cummins, Inc. is a global engine manufacturer that implemented an energy management system (EnMS) that meets the requirements of ISO 50001 and Superior Energy Performance® (SEP™).

Two North American industrial plants that recently deployed energy management systems (EnMS) are highlighted in new case studies from the Clean Energy Ministerial’s Energy Management Working Group (EMWG). These latest entries in the growing EMWG series explain how a Canadian plant, Chrysler Group LLC, and a U.S. plant, Cummins, Inc., deployed ISO 50001-compliant systems to manage energy more efficiently while boosting competitiveness. The EMWG publishes the case studies in an effort to improve energy efficiency and mitigate carbon emissions around the globe.

U.S. Case Study

Cummins, Inc. implemented an EnMS at its Rocky Mount Engine Plant, a natural gas and diesel engine manufacturing facility in Rocky Mount, North Carolina. The EnMS enabled the facility to improve energy performance by 12.6%, which saves the company USD$716,000 annually. The facility earned both ISO 50001 and SEP Gold certifications in January 2014, after an accredited third party verified the ISO 50001-compliant EnMS and energy performance improvement. View Cummins Inc. case study.

The case study provides a detailed account of the costs and savings associated with the EnMS and SEP. The facility invested USD$248,000, including USD$130,000 to purchase and install feeder breaker meters for nine electrical substations. The new meters enable better monitoring capabilities, with each business unit receiving its own energy bill. With the new EnMS, Cummins saves 99.1 billion Btu (104,600 GJ) of source energy each year. Operational savings alone paid back the investment in just 11 months, and the EnMS is expected to sustain these savings over time. 

In the case study, Cummins also shares the path it followed to plan and roll out the EnMS to help other firms learn from its experience. Activities included efforts to merge the EnMS with existing plant management systems, fund the EnMS, raise awareness, utilize the U.S. Department of Energy’s Energy Performance Indicator tool, and more. Moving forward, Cummins will expand SEP to additional facilities; it is already pursuing SEP certification at three facilities in Indiana, New York, and Minnesota. 

Canadian Case Study

Chrysler Group LLC’s Brampton assembly plant became the first automotive assembly plant in Canada to achieve ISO 50001 certification. The plant’s annual energy savings from EnMS adoption have exceeded CAD$2 million since 2013. This plant served as the pilot plant for ISO 50001 certification among Chrysler Group’s North American automotive assembly plants. View Chrysler case study.

The EnMS for the Brampton assembly plant bears all of the key components of a successful system. It includes a strategic plan for energy efficiency that requires measurement, management, and continuous improvement. The EnMS is championed by a cross-divisional team that includes a range of employees and managers. The EnMS also defines clear policies and procedures for managing energy in the facility. One example of the system’s success is key performance indicator (KPI) tracking, which is now handled through a formal, centralized, database-driven system, instead of being tracked by different people using different methods. 

Roger Matte, a plant electrician, wrote a program that starts the exhaust fans sequentially and automates a scheduled shutdown. These and other energy-saving ideas from Roger have saved the plant more than CAD$100,000.

The Brampton energy team is supported by the Chrysler Group sustainability team based in Auburn Hills, Michigan. “The Auburn Hills team is trusted on the corporate finance side. What they say carries weight, and it can help local energy teams like ours get things done,” says environmental specialist Josh Orentlicher, one of the leaders of the energy team at the plant. He adds that having a central corporate resource means local teams do not have to relearn everything from scratch.  

Funding and expertise from government agencies and utilities was also helpful in the EnMS implementation process. Natural Resources Canada supported the plant through the Office of Energy Efficiency and the Canadian Industry Program for Energy Conservation (CIPEC). By joining CIPEC, Chrysler Group gained access to energy conservation tools and services. The plant also received support and guidance from Ontario Hydro. 

About EMWG

The Clean Energy Ministerial’s Energy Management Working Group (EMWG) seeks to accelerate broad use of energy management systems (EnMS) in industry and commercial buildings worldwide. Wide adoption of these systems will deliver energy, economic, and sustainability benefits to companies, communities, and countries around the world. The EMWG’s member governments work together to identify and evaluate EnMS activities, opportunities, strategies, and best practices—working with industry and others as appropriate.