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Improved energy efficiency is one of the most effective strategies for achieving energy sustainability and independence locally, regionally and globally. Industry accounts for 40% of global energy usage each year, which suggests its potentially significant impact on overall energy use. The rapid development of standards for more efficient equipment and components are pushing manufacturers towards further improvements on a component level. However, it has been shown that the largest efficiency potential is actually found in higher system levels in which components serve, such as production processes, ventilation or hydraulic systems. Even though the importance of increasing energy efficiency at a systemic level has been widely acknowledged in recent years, practical approaches are seldom discussed in the literature. This gap between aspiration and achievement calls for the development of new approaches to foster system efficiency in industrial systems. This paper presents a systems analysis and corresponding model to increase the energy efficiency of industrial processes that involve intensive usage of electric motor systems. The model originates from traditional value stream mapping. Three case studies representing three different industrial processes were conducted to develop and validate the model. In total, 31 energy efficiency measures were identified, 29 of which address actions beyond component levels. Alongside identifications of energy efficiency measures, the model promotes the creation of conditions for cross-functional worker participation. By applying this model, the knowledge and skills gained by industrial personnel working with improved energy efficiency, maintenance and production processes can be used immediately to generate improvement suggestions. The paper concludes that this model, based on a simplified energy-focused value stream mapping, could broaden the scope of energy efficiency actions, engage a larger group of workers within the organisation and increase systems efficiency. This can be further used as a practical tool for finding continuous improvement possibilities that will result in strengthened competitiveness and more cost-effective and sustainable manufacturing. [ABSTRACT FROM AUTHOR]

Abstract: The EU has established so-called 20–20–20 targets, which in relation to energy mean that each Member State shall improve energy intensity levels by 3.3% annually, leading to a reduced primary energy use of 20% by the year 2020, calculated from a projected level based on the primary energy use in 2005. Sweden has established a less ambitious target of 1.7% annual energy intensity improvement through 2020. The aim of this paper is to evaluate, ex-ante, the EU 2020 primary energy target for the Swedish industrial sector. An applied backcasting methodology is used. The assessment made in this paper is that actions that lead to between 31.6 and 33.2 TWh/year reductions in energy end-use are needed if the EU target is to be achieved. Results from this paper shows that the current energy policy instruments are not sufficient to the EU or Swedish targets. Estimations in this paper are that a primary energy target of about 22.3 TWh/year is reasonable. The paper concludes by presenting a roadmap on how the Swedish 2020 target can be achieved through: i) energy management; ii) energy-efficient technology; and iii) energy supply measures, with an approximate cost of 280–300 MEUR or 75–80 kWh per public EUR. Three major additional policy measures are needed compared with the current policy: including all energy carriers, not just electricity, in the Swedish long-term agreements program PFE; setting up networks; and making it possible for third parties, i.e., industry, to deliver excess heat into the monopolized Swedish district heating grids. [Copyright &y& Elsevier]