Cummins Inc. Saves $200K Annually Using Energy-Efficient Motors

Mention Cummins engines to anyone who's ever put the pedal to the metal in an 18-wheeler and you'll probably hear words like value and efficiency. So, it shouldn't come as a surprise that Cummins Inc. also practices energy efficiency in its plants. Cummins management believes a proactive energy efficiency policy helps the company stay competitive.


Mention Cummins engines to anyone who's ever put the pedal to the metal in an 18-wheeler and you'll probably hear words like value and efficiency. So, it shouldn't come as a surprise that Cummins Inc. also practices energy efficiency in its plants. Cummins management believes a proactive energy efficiency policy helps the company stay competitive.

In fact, Cummins' energy savings have been so remarkable, the U.S. Department of Energy's (DOE) Office of Industrial Technologies (OIT) granted the company its Industry Captains Command Award in 1999. This article describes how Cummins reduced energy consumption, created real benefits to the environment, and saved more than $200,000 per year in energy costs. And those savings wouldn't have been possible without copper.

Working with Your Utility

Cummins' award-winning energy program began in 1987. Public Service of Indiana (PSI) did a survey to determine where Cummins could reduce its energy consumption. Besides a number of beneficial changes, PSI recommended DOE's Motor Challenge program. Since electric-motor-driven equipment consumes about 60% of all electricity produced in the USA, increasing motor efficiency by even a few percent adds up to big savings.

How big? DOE's Paul Scheihing notes, "If every plant in the United States integrated motor system upgrades to the extent that Cummins did, American industry would save $1 billion annually in energy costs. This would be the equivalent of the amount of electricity supplied to the State of New York for three months."

Working with Motor Challenge

Cummins became actively involved with Motor Challenge in 1995 at its main plant in Columbus, Indiana, and the 296 motors that drive the plant's engine block machining and transfer lines. While the line's electric motors were reliable enough, their efficiency ratings were typical of those available 30 years ago.

"We studied the Motor Challenge information thoroughly. In the end, we got to the point where we realized we'd be better off throwing these things out," recalls Tim Burke, Cummins director of administration and finance. That meant getting rid of more than 1,000 motors, including all spares as well as those in service.

Working with Your Consultant

Cummins brought in McBroom Electric Company of Indianapolis to take a close look at every motor on the production lines. Their audit projected that Cummins would save $80,000 per year in power costs by replacing all of the lines' 1- to 125-hp standard-efficiency motors with energy-efficient motors.

Table 1 shows the results of Cummins' motor-upgrade program. They provide dramatic proof that improved efficiency yields big savings. Table 2 shows the results of Cummins next step, which was to replace 500 motors ranging in size from

Life-Cycle Costing

Cummins Inc. has an in-house standard for life-cycle costing of equipment. "In the case of energy-efficient motors," Burke says, "annual energy savings provided the major incentive. But since installing the motors,… we now have all new motors in our upgraded transfer lines, so maintenance costs have been reduced, … and we can now point to the reduction in fossil fuel use and lower greenhouse gas emissions brought about by our energy-efficient motors as evidence of our corporate environmental awareness."

What's Available from CDA

Like Cummins Inc., your company can benefit from the greater energy savings provided by energy-efficient electric motors. Read and download the complete Cummins case study and other success stories on the Web at .

For a free copy of MotorMaster+ software, information on NEMA Premium motor guidelines and other sources to help you get maximum returns on your motor investment, call the Copper Development Association at: 888-480-MOTR (888-480-6687).

The Top Plant program honors outstanding manufacturing facilities in North America. View the 2015 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
Pipe fabrication and IIoT; 2017 Product of the Year finalists
The future of electrical safety; Four keys to RPM success; Picking the right weld fume option
A new approach to the Skills Gap; Community colleges may hold the key for manufacturing; 2017 Engineering Leaders Under 40
Control room technology innovation; Practical approaches to corrosion protection; Pipeline regulator revises quality programs
The cloud, mobility, and remote operations; SCADA and contextual mobility; Custom UPS empowering a secure pipeline
Infrastructure for natural gas expansion; Artificial lift methods; Disruptive technology and fugitive gas emissions
Power system design for high-performance buildings; mitigating arc flash hazards
VFDs improving motion control applications; Powering automation and IIoT wirelessly; Connecting the dots
Natural gas engines; New applications for fuel cells; Large engines become more efficient; Extending boiler life

Annual Salary Survey

Before the calendar turned, 2016 already had the makings of a pivotal year for manufacturing, and for the world.

There were the big events for the year, including the United States as Partner Country at Hannover Messe in April and the 2016 International Manufacturing Technology Show in Chicago in September. There's also the matter of the U.S. presidential elections in November, which promise to shape policy in manufacturing for years to come.

But the year started with global economic turmoil, as a slowdown in Chinese manufacturing triggered a worldwide stock hiccup that sent values plummeting. The continued plunge in world oil prices has resulted in a slowdown in exploration and, by extension, the manufacture of exploration equipment.

Read more: 2015 Salary Survey

Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Society for Maintenance and Reliability Professionals an organization devoted...
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
The maintenance journey has been a long, slow trek for most manufacturers and has gone from preventive maintenance to predictive maintenance.
This digital report explains how plant engineers and subject matter experts (SME) need support for time series data and its many challenges.
This digital report will explore several aspects of how IIoT will transform manufacturing in the coming years.
Maintenance Manager; California Oils Corp.
Associate, Electrical Engineering; Wood Harbinger
Control Systems Engineer; Robert Bosch Corp.
This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
click me