U.S. Department of Energy - Energy Efficiency and Renewable Energy

Industrial Technologies Program

Industrial Assessment Centers

Assessment #MO0200


Assessment Year 1997
SIC 3714
SIC Description Motor Vehicle Parts And Accessories
NAICS
NAICS Description
Principal Product Components for Axles, Light Trucks and Heavy Pick-UP Trucks
Sales $ 55,350,000
# of Employees 370
Plant Area (Sq.Ft.) 140,000
Annual Production 3,400,000 Pieces
Production Hrs. Annual 7,700
Location (State) MO
Yearly Energy Cost $ 601,104

Current Energy Usage & Costs

Energy Sources Yearly Usage Yearly Cost Unit Price

Electricity

 4,890,387 kWh $ 176,632 $ 0.036 /kWh

- Demand Charge

 989 kW $ 49,134 $ 49.68 /kW

- Electricity Fees

 - $ 15,109 -

Natural Gas

 116,035 MMBtu $ 360,229 $ 3.10 /MMBtu

TOTAL ENERGY

 166,161 MMBtu $ 601,104 $ 3.62 /MMBtu

Solid Waste (non-haz)

 100,440 lbs $ 11,544 $ 0 /lbs

Recommended Reduction in Usage & Costs

Recommended
Implemented
Energy Sources Yearly Savings Yearly Cost % Saved Unit Price

Electricity

 257,620 kWh
257,620 kWh		 $ 10,102
$ 10,102		 5.72 %
5.72 %		 $ 0.036 /kWh

- Demand Charge

 44 kW
44 kW		 $ 2,095
$ 2,095		 4.26 %
4.26 %		 $ 49.68 /kW

- Electricity Fees

 - $ 0
$ 0		 0.00 %
0.00 %		 -

Natural Gas

 0 MMBtu
0 MMBtu		 $ 0
$ 0		 0.00 %
0.00 %		 $ 3.10 /MMBtu

TOTAL ENERGY

 2,641 MMBtu
2,641 MMBtu		 $ 12,197
$ 12,197		 2.03 %
2.03 %		 $ 3.62 /MMBtu

Solid Waste (non-haz)

 12,960 lbs
0 lbs		 $ 11,544
$ 0		 100.00 %
0.00 %		 $ 0 /lbs

Recommendations

AR # Description ARC Code Status Cost Savings Payback
(Years)
01 view
details		 CROSS-TRAIN PERSONNEL TO AVOID LOST TIME 4.4320 I $ 20,000 $ 22,150 0.90
Energy Sources Yearly Reduction Yearly Savings Unit Price

Ancillary Material Cost

 - $ 22,150 -

TOTAL PRODUCTON

 - $ 22,150 -
02 view
details		 INITIATE A TOTAL QUALITY MANAGEMENT PROGRAM 4.7110 I $ 15,000 $ 17,554 0.85
Energy Sources Yearly Reduction Yearly Savings Unit Price

Ancillary Material Cost

 - $ 17,554 -

TOTAL PRODUCTON

 - $ 17,554 -
03 view
details		 BEGIN A PRACTICE OF PREDICTIVE / PREVENTATIVE MAINTENANCE 4.6110 I $ 5,500 $ 13,440 0.41
Energy Sources Yearly Reduction Yearly Savings Unit Price

Ancillary Material Cost

 - $ 13,440 -

TOTAL PRODUCTON

 - $ 13,440 -
04 view
details		 RE-ARRANGE EQUIPMENT LAYOUT TO REDUCE HANDLING COSTS 4.5140 N $ 10,000 $ 4,050 2.47
Energy Sources Yearly Reduction Yearly Savings Unit Price

Ancillary Material Cost

 - $ 4,050 -

TOTAL PRODUCTON

 - $ 4,050 -
05 view
details		 INSTALL COMPRESSOR AIR INTAKES IN COOLEST LOCATIONS 2.4221 I $ 333 $ 7,176 0.05
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 151,231 kWh $ 5,924 $ 0.036 /kWh

- Demand Charge

 25 kW $ 1,252 $ 49.68 /kW

TOTAL ENERGY

 1,550 MMBtu $ 7,176 -
06 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 4,216 $ 1,809 2.33
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 38,687 kWh $ 1,518 $ 0.036 /kWh

- Demand Charge

 6 kW $ 291 $ 49.68 /kW

TOTAL ENERGY

 397 MMBtu $ 1,809 -
07 view
details		 USE MORE EFFICIENT LIGHT SOURCE 2.7143 I $ 345 $ 151 2.28
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 3,224 kWh $ 131 $ 0.036 /kWh

- Demand Charge

 1 kW $ 20 $ 49.68 /kW

TOTAL ENERGY

 33 MMBtu $ 151 -
08 view
details		 UTILIZE HIGHER EFFICIENCY LAMPS AND/OR BALLASTS 2.7142 I $ 179 $ 164 1.09
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 3,517 kWh $ 139 $ 0.036 /kWh

- Demand Charge

 1 kW $ 25 $ 49.68 /kW

TOTAL ENERGY

 36 MMBtu $ 164 -
09 view
details		 UTILIZE ENERGY-EFFICIENT BELTS AND OTHER IMPROVED MECHANISMS 2.4111 I $ 0 $ 991 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 20,809 kWh $ 817 $ 0.036 /kWh

- Demand Charge

 4 kW $ 174 $ 49.68 /kW

TOTAL ENERGY

 213 MMBtu $ 991 -
10 view
details		 USE MOST EFFICIENT TYPE OF ELECTRIC MOTORS 2.4133 I $ 4,214 $ 1,906 2.21
Energy Sources Yearly Reduction Yearly Savings Unit Price

Electricity

 40,152 kWh $ 1,573 $ 0.036 /kWh

- Demand Charge

 7 kW $ 333 $ 49.68 /kW

TOTAL ENERGY

 412 MMBtu $ 1,906 -
11 view
details		 RECOVER AND REUSE WASTE MATERIAL 3.5311 N $ 0 $ 9,720 0.00
Energy Sources Yearly Reduction Yearly Savings Unit Price

Solid Waste (non-haz)

 9,720 lbs $ 9,720 $ 0 /lbs

TOTAL WASTE

 - $ 9,720 -
12 view
details		 INITIATE A TOTAL QUALITY MANAGEMENT PROGRAM 4.7110 N $ 2,200 $ 1,824 1.21
Energy Sources Yearly Reduction Yearly Savings Unit Price

Solid Waste (non-haz)

 3,240 lbs $ 1,824 $ 0 /lbs

TOTAL WASTE

 - $ 1,824 -