A Diagnostic Approach to Improving the Energy Efficiency of Production Processes—2E-DAmIcS Methodology

Abstract

This article presents the issue of energy waste in manufacturing processes, focusing on reducing unnecessary energy consumption and CO2 emissions. A significant challenge in modern production is identifying and minimizing energy waste, which not only increases operational costs but also contributes to environmental degradation. An improvement methodology referred to as 2E-DAmIcS is proposed. A distinguishing feature of the methodology is a risk map of energy waste in the production process. Application of the methodology is demonstrated using the example of a lead–acid battery production process. It is shown that even small but well-diagnosed changes to the process make it possible to significantly reduce energy consumption. The proposed methodology offers practical tools for managers and decision-makers in various industries to systematically identify and minimize energy waste. It highlights the importance of cross-disciplinary collaboration among specialists in technology, energy consumption, and statistical analysis to optimize energy use. By applying this approach, companies can achieve both financial savings and environmental benefits, contributing to more sustainable production practices.