Implementation of a Corporate Energy Accounting and Forecasting Model

The development and implementation of a Frito-Lay computer based energy consumption reporting and modeling program is discussed. The system has been designed to relate actual plant energy consumption to a standard consumption which incorporates the effects of weather, product mix, specific equipment types, and other plant factors. The model also provides energy consumption forecasts based on projected production, equipment improvements, and fuels mix. Development of the model began in August 1979 and was preceded by two years of complete auditing of all areas in two manufacturing plants plus specific processing lines in other plants to determine typical energy usage. Extensive analyses of the data resulted in the formulation of standards for the various pieces of equipment which are used as energy performance 'yardsticks'. Monthly reports permit equitable comparisons of plant energy consumption and isolation of those plants with the lowest efficiencies. The financial impact of increasing energy consumption, of the projected energy use for new plants or plant expansions, and of the effect of process changes on overall energy consumption can be also evaluated.