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A review of the current automotive manufacturing practice from an energy perspective

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  • Giampieri, A.
  • Ling-Chin, J.
  • Ma, Z.
  • Smallbone, A.
  • Roskilly, A.P.

Abstract

The automotive industry is facing on-going challenges to improve the sustainability of its manufacturing processes and vehicle emissions due to economic, environmental, marketability and policy concerns. This review aims to evaluate steps that could be taken by automotive manufacturers to further reduce energy consumed during manufacturing processes, particularly focusing on thermal management of low-temperature heat sources that are extensively present in the whole plant and in the paint shop. Through an extensive literature review on the subject, this article presents vehicle production processes, the past and future drivers, and strategies towards sustainability. Firstly, the whole vehicle manufacturing process is explained focusing on the energy sources and their use in the plant. Then, the paint shop is described as being responsible for the highest energy consumption in the production process, focusing on components, paints and energy utilisation. After presenting the practice performed by automotive manufacturers to reduce the energy consumption of their production process in terms of energy efficiency and thermal management, the article is closed by future steps that could be undertaken by the automotive industry towards the realisation of a low-carbon sector. It is concluded that unexploited potential for heat recovery in the paint shop is present in the low-temperature range and this waste heat could be effectively exploited by liquid desiccant technology for energy consumption reduction and could increase paint quality of the painting process due to more efficient moisture control.

Suggested Citation

  • Giampieri, A. & Ling-Chin, J. & Ma, Z. & Smallbone, A. & Roskilly, A.P., 2020. "A review of the current automotive manufacturing practice from an energy perspective," Applied Energy, Elsevier, vol. 261(C).
    • Handle: RePEc:eee:appene:v:261:y:2020:i:c:s0306261919317611
    DOI: 10.1016/j.apenergy.2019.114074
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    4. Sindu Daniarta & Piotr Kolasiński & Barbara Rogosz, 2022. "Waste Heat Recovery in Automotive Paint Shop via Organic Rankine Cycle and Thermal Energy Storage System—Selected Thermodynamic Issues," Energies, MDPI, vol. 15(6), pages 1-18, March.
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    13. Liu, Weipeng & Peng, Tao & Kishita, Yusuke & Umeda, Yasushi & Tang, Renzhong & Tang, Wangchujun & Hu, Luoke, 2021. "Critical life cycle inventory for aluminum die casting: A lightweight-vehicle manufacturing enabling technology," Applied Energy, Elsevier, vol. 304(C).
    14. Zhaohui Feng & Xinru Ding & Hua Zhang & Ying Liu & Wei Yan & Xiaoli Jiang, 2023. "An Energy Consumption Estimation Method for the Tool Setting Process in CNC Milling Based on the Modular Arrangement of Predetermined Time Standards," Energies, MDPI, vol. 16(20), pages 1-18, October.
    15. Meihang Zhang & Hua Zhang & Wei Yan & Zhigang Jiang & Shuo Zhu, 2023. "An Integrated Deep-Learning-Based Approach for Energy Consumption Prediction of Machining Systems," Sustainability, MDPI, vol. 15(7), pages 1-17, March.
    16. Francesco Pelella & Luca Viscito & Federico Magnea & Alessandro Zanella & Stanislao Patalano & Alfonso William Mauro & Nicola Bianco, 2023. "Comparison between Physics-Based Approaches and Neural Networks for the Energy Consumption Optimization of an Automotive Production Industrial Process," Energies, MDPI, vol. 16(19), pages 1-22, September.
    17. Su, Xing & Geng, Yining & Huang, Lei & Li, Shangao & Wang, Qinbao & Xu, Zehan & Tian, Shaochen, 2024. "Review on dehumidification technology in low and extremely low humidity industrial environments," Energy, Elsevier, vol. 302(C).
    18. Ronaldo Nilo Miyagi Martire & Mustafa Erguvan & Shahriar Amini, 2024. "A 4E Analysis of a Solar Organic Rankine Cycle Applied to a Paint Shop in the Automotive Industry," Energies, MDPI, vol. 17(17), pages 1-23, August.
    19. Pi, Dawei & Xue, Pengyu & Wang, Weihua & Xie, Boyuan & Wang, Hongliang & Wang, Xianhui & Yin, Guodong, 2023. "Automotive platoon energy-saving: A review," Renewable and Sustainable Energy Reviews, Elsevier, vol. 179(C).
    20. Rajesh Mehta & Milad Golkaram & Jack T. W. E. Vogels & Tom Ligthart & Eugene Someren & Spela Ferjan & Jelmer Lennartz, 2023. "BEVSIM: Battery electric vehicle sustainability impact assessment model," Journal of Industrial Ecology, Yale University, vol. 27(5), pages 1266-1276, October.
    21. Albert, Max D.A. & Bennett, Katherine O. & Adams, Charlotte A. & Gluyas, Jon G., 2022. "Waste heat mapping: A UK study," Renewable and Sustainable Energy Reviews, Elsevier, vol. 160(C).
    22. Andrei, Mariana & Rohdin, Patrik & Thollander, Patrik & Wallin, Johanna & Tångring, Magnus, 2024. "Exploring a decarbonization framework for a Swedish automotive paint shop," Renewable and Sustainable Energy Reviews, Elsevier, vol. 200(C).
    23. Silvia Carpitella, 2024. "Overcoming Barriers to Digital Transformation towards Greener Supply Chains in Automotive Paint Shop Operations," Sustainability, MDPI, vol. 16(5), pages 1-20, February.

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