Energy management for manufacturing


Overview of ‘Energy management for manufacturing’

Energy efficiency is one of the ‘hot’ topics of the 21st century and manufacturing processors around the world are trying to come to terms with it.

The possible savings from good energy management are in the range of 30% of current energy expenditures for most processors. In extreme cases, energy savings of up to 50% have been identified with little difficulty.

The measures identified are a mix of short-term rapid payback actions (payback of less than 6 months) and longer-term payback actions (payback of around 18 months).

This energy management training course is designed to help set your organisation on the path of reduced energy costs.

Training objectives

This course will help you:
  • Appreciate the costs and the wider significance of energy consumption
  • Give you an idea as to the practical ways in which you can reduce consumption
  • Help you create action plans for immediate implementation at the appropriate levels: general management, monitoring and targeting, services and site, operations

Effective development and implementation of the plans on which you will start working in this course will save your organisation a significant amount of money as well as creating wider benefits for both the organisation and the environment.


This course is ideal for senior managers and those working in HSE and manufacturing services roles, but is also suitable for anyone working in manufacturing.


An interactive one-day energy management training programme which includes a practical session.

Special features

For maximum return on investment, we suggest that the trainer perform a site survey in advance of the energy management training taking place.

The expert trainer

Robin is an energetic, inspiring trainer and consulting engineer specialising in energy management for manufacturing operations. He was awarded the Plastics Industry Awards 2010 ‘Personal Contribution’ award for his work as a champion of energy efficiency and for helping numerous processors to make savings through better energy use.

He has an international reputation and his consulting and training work takes him around the world, with a particular emphasis on North and South America.

Robin has a BEng (Hons) in Materials Engineering from Monash University in Australia and a PhD in Solid State Physics (Polymer Physics) from the University of Surrey. He has published over 400 technical papers and articles and written two books: Cost Management in Plastics Processing (2007) and Energy Management in Plastics Processing: Strategies, Targets, Techniques and Tools (2008). He currently sits on the Research Committee of the Centre for Window and Cladding Technology (CWCT) and is the immediate past Chairman of the Plastics Consultancy Network. He is a Fellow of the Institution of Materials, Minerals and Mining, a Liveryman of the Worshipful Company of Horners and a Freeman of the City of London.

Course outline – Energy management for manufacturing

Note: this is a generic outline, based on the trainer’s open course. When run on an in-house basis, the ‘Energy management for manufacturing’ programme is completely tailored to the client’s specific requirements.

1   Introduction: corporate and legal context
(jointly with HSE manager)

2   Management issues
  • Exercise: Creating the Energy Inefficient Organisation
  • The rising importance of energy costs
  • The drivers
  • What can we save?
  • How valuable are these savings?
  • The Carbon Footprint
  • The costs and efforts
  • The vital questions
  • The management actions
  • Key tips for management
  • Energy, financial and technical management – where are we now?
  • Awareness and information – where are we now?
  • Action plan for general management
3   Monitoring and targeting
  • The basic data
  • Reading the PCL
  • Assessing current performance
  • Assessing past performance
  • Budgeting
  • Performance characteristic lines
  • Reporting
  • Integrating energy into the accounts
  • Targeting and controlling – where are we now?
  • Action plan for monitoring and targeting
4   Services and site
  • The total costs
  • Power supply and motors
  • Compressed air
  • Chilled and cooling water
  • Materials
  • Lighting
  • Key tips for services
  • Action plan for services and site
  • Exercise: Variable Frequency Drives
5   Operations
  • Initial machine setting
  • Start-up, standby & shut-down
  • Setting sheets
  • Key tips for operations
  • Action plan for operations
6   Practical session
  • The energy walk-around

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