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.