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Toyota Motor Engineering & Manufacturing North America, Inc.:

Step 2 - Assess Performance

2: Assess Performance

Assessing Major Energy Uses

The majority of Toyota's energy consumed is in the paint and casting shops where more than 80 percent of the energy used is fixed regardless of the number of vehicles produced.  Per a request of Toyota's Production Engineering Vice President, a custom energy analysis was created to compare energy use by assembly line.  The report depicted a large energy difference between two paint shops in an assembly plant making the same vehicle. 

As a result, the Energy Process Assessment was created to identify precisely where each process is using energy.  The process calculates the energy efficiency of each machine establishing a current state.  Then key drivers of energy use are studied and benchmarked against other lines or plants to identify causes of low efficiency.  And finally, countermeasures to the key drivers are developed to jump start implementation and improve the efficiency of the machine and overall process.  Reduction opportunities of 400,000 MMBtus have been identified as a result of this process.

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