Saving Energy at Ford

Abstract

Today's emphasis is on saving dollars -- not just Btu's. Ford spent $900 million on energy in 150 plants worldwide last year. In 1972, Ford's energy bill was $238 million. Last year's bill would have been 35% higher than $900 million, if it had not been for conservation since 1972. First steps were cutting out obvious waste; e.g., repairing steam and compressed-air leaks, shutting down equipment promptly at end-of-shift, and lowering building temperatures -- simple measures that cost little but saved 25% of energy. Other steps included boiler tune-ups, improved combustion controls, weekend and summer boiler shutdown, steam trap surveys, automatic motor shutoff timers, fast-acting fabric traffic doors, and area metering. Steps requiring greater investment included energy management systems, waste incinerators with heat recovery, cogeneration and variable-frequency drives. Much pioneering work was done on self-help gas, negotiating reduced utility rates and rate case interventions. Employee awareness and involvement are essential. Regular energy council meetings and an attractive energy newsletter also help.