Hunt for Energy Efficiencies, people

The Hunt is On for Energy Efficiencies

  • The Hunt is On for Energy Efficiencies

Every Nook. Every Cranny. Every Bit Counts when Hunting for Energy Savings.

In 2017, FCA launched a global initiative to identify and implement energy savings practices. The “Treasure Hunt” provides the Company a complete assessment of our energy improvement opportunities.

An Energy Treasure Hunt, as defined by the U.S. Environmental Protection Agency’s Energy Star® Treasure Hunt playbook, is an onsite event in which cross-functional teams of employees identify day-to-day operational energy efficiency improvements. Treasure Hunts focus on improvements that can often be made immediately and without significant expenditures. The “hunts” also evaluate energy use during non-operating hours, when most energy waste occurs.

First piloted in September 2017 at the Company’s Jefferson North Assembly Plant, where the Jeep® Grand Cherokee, Jeep® Grand Cherokee SRT and Dodge Durango are built, “Treasure Hunts” have become a low-cost, high-impact initiative that are building awareness and installing a culture of continuous improvement with our employees to help reduce our energy use.

Treasure Hunts
€5.5 Million
Savings Identified

Infographic about FCA's most efficient Manufacturing Plants

In July 2018, a global team made up of 30 facility managers and EHS specialists, whom we call our “Energy Champions,” embraced the adventure and conducted a treasure hunt at one of the most efficient plants in the Group: the Tychy Assembly Plant in Poland where the Fiat 500, Lancia Ypsilon and Abarth 500 are manufactured. In addition to generating the lowest energy used per vehicle produced, Tychy Assembly Plant also received World Class Manufacturing (WCM) Gold status in 2013.

WCM is an approach that applies to all areas of the facility and seeks to eliminate waste and increase the productivity, well-being, and safety of the individuals who work there. The success of WCM is highly dependent on the participation of employees, who are involved in targeted training programs in order to properly apply WCM methods.

The Hunt is On for Energy Efficiencies - group and Fiat 500

The global team, comprised of employees from 12 countries, scrutinized every piece of data and every centimeter of the paint shop, assembly area, body shop, and energy centers over the course of three days. They accomplished this by breaking up into five groups so each group could focus on one designated area within the plant. They then dug into the details to unearth best practices and pinpoint energy waste in our systems, processes and equipment.

The Energy Champions also benchmarked the plant’s automated hot water systems for heating, its ventilation and air conditioning (HVAC) processes, the electric heating system for adhesive materials, and the heat recovery scheme, among other things.
After analyzing the results, the team identified 33 lessons learned and found more than 90 energy-savings opportunities.

One of the most notable best practices found during the hunt was the plant’s industry-leading practice where the heating system can quickly ramp up and ramp down various areas of the plant to save energy, while not compromising quality, especially in the paint shop where temperature changes can dramatically impact quality. This process, among others, was shared globally and is now being used at 10 FCA facilities.

Once back in their home country, Energy Champions began rolling out the best practices in their local facilities. Meanwhile, the Tychy plant started implementing their identified energy improvements and are already seeing a three percent reduction in energy costs.

Countries Represented
by FCA Energy
Champion Participants
Energy Savings Identified
Energy-Savings Opportunities Found

Ongoing Efforts to Reduce Energy Waste

Due to the success of this initiative, FCA expects to implement similar programs at 12 facilities in 2019.
“Treasure hunts” are just one of the tools FCA is using to achieve a 30 percent reduction in energy consumed per vehicle produced versus 2010 at mass-market vehicle assembly and stamping plants worldwide by 2020. As we continue to seek solutions to reduce our use of fossil fuels, we are seeing significant savings and progress: by the end of 2017, FCA’s energy consumption was down 24% compared with 2010.

This story highlights concrete evidence of FCA’s sustainability commitment and its alignment with the principles of the United Nations 2030 Agenda and the following Sustainable Development Goals:

Sustinability Goals: 7 - Affordable and Clean Energy; 9 - Industry, Innovation and Infrastructure; 12 - Responsable Consumption and Production; 13 - Climate Action

November 2018

Related Stories

Water, a Shared Responsibility

Read More

Jeep®​​​​ Plant in Brazil is Carbon Neutral

Read More