The document summarizes the results of the first phase of the EuroEnergest project, which aims to reduce energy consumption in the automotive industry by 10% through an intelligent Energy Management System (iEMS). It describes the car manufacturing process and energy usage. The iEMS will be tested at the SEAT Martorell factory in Barcelona, focusing on the bodyshop and painting workshops. The analysis found the automotive industry profile is dynamic and non-homogeneous, and the iEMS modular structure allows application in different situations. The project will now enter the software implementation and testing phase at SEAT facilities.

1. Public Report on WP1
Deliverable D1.3 / WP1 / TASKs 1.1 / 1.2 / 1.3
INCREASE OF AUTOMOTIVE CAR INDUSTRY COMPETITIVENESS THROUGH
AN INTEGRAL AND ARTIFICIAL INTELLIGENCE DRIVEN ENERGY
MANAGEMENT SYSTEM
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2. 2. The car manufacturing industry
1. Introduction
2
Index
3. The “intelligent Energy Management System (iEMS)
4. The pilot plant: SEAT Martorell
5. Conclusions and next steps

3. 1.1 EuroEnergest Project
1.2 Project Consortium
1. Introduction
3
Index
2. The car manufacturing industry
3. The “intelligent Energy Management System (iEMS)
4. The pilot plant: SEAT Martorell
5. Conclusions and next steps

4. This report presents the main results and conclusions of the
work done during the first period of the project EuroEnergest.
This document shows:
 The results from the automotive industry analysis.
 The general structure of an iEMS and its advantages for
energy management.
 A description of the SEAT Martorell plant where the system
will be tested.
 The process to implement the EuroEnergest software in the
car manufacturing industry.
1. Introduction
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5. The aim of the project is to
reduce, at least by 10%, the
energy consumption in the
automotive industry by
developing an intelligent
Energy Management System
(iEMS).
1.1 EuroEnergest Project
This development will be implemented on a
real site (SEAT facilities, in the outskirts of
Barcelona – Spain) for its industrial trials and
validation.
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6. The EuroEnergest project is a
collaborative project between
technology centres, universities and
private companies to develop a
system of intelligent energy
management for the automotive
industry.
This project is supported by the European
Commission under the 7th Framework
Programme
1.2 Project Consortium
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7. 2.1 The car manufacturing process
2.1 Energy and environmental impact
1. Introduction
Index
2. The car manufacturing industry
3. The “intelligent Energy Management System (iEMS)
4. The pilot plant: SEAT Martorell
5. Conclusions and next steps
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8. Generally speaking, there is not one automotive manufacturing
plant which is exactly like any other. Some similarities can be found
among recently built ones but the old plants have been regularly
updated to cope with constantly changing market needs.
2. The car manufacturing industry
Initially, fully integrated
factories were constructed,
but over the years, the
outsourcing process has
generally extended and
many production steps
have been externalized to
other companies.
The profile of industrial plants is very dynamic and
not a homogeneous facility. This is one of the
biggest challenges of the EuroEnergest project:
“to be flexibly enough in order to be adapted to
this heterogeneous environment” 8

9. Despite the fact that all car manufacturing processes can
be standardized, they are not necessarily located within the
same production environment.
2.1 The car manufacturing process
Logistics (material
receipt)
Press Bodyshop Painting Assembly
Quality
review
Logistics
(car
distribution)
These vehicle production systems
continue operating with the same
logic but the difference is that
some of their internal processes
have been outsourced or there has
been an improvement in terms of
the technology used.
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10. With regards to energy consumption, during
2011 the average energy consumption for the
production of a vehicle was 2,5 MWh (from
data from major vehicle manufacturers).
Variances above and below this typical value
may be due both to the difference between
vehicle models and the difference in the
production process.
2.1 Energy and environmental impact
From an environmental viewpoint, the
resulting CO2 emissions from the production
of vehicles, is 0,65 tons of CO2 per vehicle.
Since there is a direct relationship between
energy consumption and CO2 emissions, it
can be assumed that the differences are due
to the mix of primary energy sources used.
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11. 1. Introduction
11
Index
2. The car manufacturing industry
3. The “intelligent Energy Management System (iEMS)
4. The pilot plant: SEAT Martorell
5. Conclusions and next steps

12. 3. The “intelligent Energy Management System (iEMS)
An Energy Management System (EMS) is a set of tools
used to manage a facilities energy information.
Perhaps most importantly, intelligent energy management provides a
platform that empowers real-time insight, analysis and control, as
well as integration with the expanding smart grid infrastructure.
Intelligent energy
management solutions
build on traditional and
informed demand
response practices by
incorporating several new
elements that help
energy sources and
energy consuming
systems leverage a true,
two-way dialogue.
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13. 3. The “intelligent Energy Management System (iEMS)
EuroEnergest software uses information
from different sources. Most important of
these are weather databases, and data
about the production plan.
This information needs to be continually
updated by means of an online server.
Unfortunately, industrial processes carried
out in the automotive sector are subject to
strict privacy policies, leading to the
introduction of limitations on information
availability.
For this purpose a distributed software implementation across different servers
has been chosen, to enhance the protection of the company's confidential data
from external attack.
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14. 14
3. The “intelligent Energy Management System (iEMS)
As the software design is conceptualized today, a number of finite elements
(energy generation/consumption equipment) are modeled.
If required, it is possible to incorporate new models, such as the introduction of
further types of renewable energy generation systems.
The EuroEnergest iEMS aims to combine available energy
sources (electrical/gas grid, renewable and CHP) to supply the
energy demand in a car manufacturing environment. 14

15. 1. Introduction
15
Index
2. The car manufacturing industry
3. The “intelligent Energy Management System (iEMS)
4. The pilot plant: SEAT Martorell
4.1 Assembly
4.2 Painting
5. Conclusions and next steps

16. 4. The pilot plant: SEAT Martorell
The EuroEnergest project will be
implementable in any car
manufacture industry, but the first
industrial scale trials will be done
at the SEAT Martorell factory.
This SEAT factory covers a total
of over 2.800.000 m2.
The project will be focused on
Bodyshop and Painting
workshops which will be fully
analyzed and monitored.
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17. 4. The pilot plant: SEAT Martorell
The primary energy
consumption at SEAT is 700
GWh, with gas being the most
highly used energy source (550
GWh) representing a 78%. The
remaining 22% is electricity
from the grid (150 GWh).
Part of gas supply is used to
generate overheated water and
electricity in the CHP.
In terms of energy consumed in
each workshop (540 GWh),
electricity is the most high
demand source (260 GWh) with
the 48% of the total consumed,
followed by thermal energy
(200 GWh) with 37% and gas
(80 GWh) with 15% 17

18. 4.1 Bodywork
With regards to the two
workshops where the
EuroEnergest system will be
implanted, the bodywork
processes take place in the
100.000 m2 of the workshops 1.
Its main purpose is to give
corrosion resistance, geometry
and sealing to the cars structure.
More than 1.800 employees
work together with 3.000
robots.
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19. 4.2 Painting
In the Painting process, more than 1.000 people work to get
2.000 cars painted every day. Approximately 75 robots are
used to paint each car during the different process steps.
The painting process is the most intensive in terms of electricity,
thermal energy, gas and water consumption. The percentage of gas
used (around 30%), is much higher than the average of the other
workshops. This is due to the fact that some ovens use gas directly to
provide high temperatures.
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20. 1. Introduction
20
Index
2. The car manufacturing industry
3. The “intelligent Energy Management System (iEMS)
4. The pilot plant: SEAT Martorell
5. Conclusions and next steps

21. 5. Conclusions and next steps
The analysis done on WP1 concludes that:
One of the biggest challenges of EuroEnergest project is that the profile of
industrial plants is a very dynamic and non-homogeneous
As the EuroEnergest software is conceptualized today, a number of finite
elements (energy generation/consumption equipment) are modeled and it is
this modular structure which allows the solution of a wide range of
situations.
Painting and Bodywork workshop have been selected at SEAT due to their
differences in energy use in their HVAC systems. They represent both the use of
HVAC for comfort and process.
There are significant differences between the energy used and the CO2
emission per car manufactured, but these differences may be due to
differences in processes and the wide range and type of vehicles
manufactured.
1
2
3
4
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22. ProjectProgress
5. Conclusions and next steps
The following diagram shows the methodology, in general terms, to be
used to implement the software in a car manufacture industry.
STAGE 1
STAGE 2
STAGE 3
STAGE 4
STAGE 5
STAGE 6
ANALYSIS
SOFTWARE
IMPLEMENTATION
ON-LINE MODELLING
AND DATA ACQUISITION
PLAN
IEMS TEST AND
REFINEMENT
EVALUATION AND
REPORTING
EXPLOITATION
The car manufacturer provides information about the plant
First energy models are defined
Critical constrains and relevant variables are studied.
Relationships with different models are defined into the iEMS structure.
Historical and Real data is collected to define specific generation/consumption
models.
First models outputs are used to define on-line models.
Extra measurements are detected and a data acquisition plan is defined.
iEMs is implemented at SEAT facilities and plugged to live data.
The first results allow to test and refine the iEMS operation.
iEMS software is trialled and its performance is evaluated.
Energy savings and CO2 emissions are reported and validated.
The software is examined to determine its ability to be adapted to other
environments and necessary modifications are defined.
The software is prepared for its exploitation and sale to potential customers in
automotive industry.
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http://www.euroenergest.eu/
info@euroenergest.eu