Design of processes and systems must include integration and interconnectivity with available energy and material flows

A manufacturing plant has many processes and many products manufactured simultaneously. Some of the processes may produce excess heat that can be used elsewhere in another process. Similarly, one area may be producing excess material that can be shared with another area as raw material.

Some of the examples are: Using municipal waste to produce methane for heating, automobile radiator heat is used to warm the occupant compartment, using wood chips to make compressed boards, etc.

Although the integration and interconnectivity with available energy and material flow seems intuitive and makes sense, execution of such strategy requires holistic knowledge of manufacturing processes and products is required. A successful company which applies this principle typically manages both product and process data centrally and able to identify opportunities continually.