From Energy Saving to Sustainability: Auto State’s Smart Manufacturing and Energy Management Practices

Founded in 1994, Auto State International Co., Ltd. has long specialized in the development and production of aftermarket parts and accessories for a wide range of renowned motorcycle brands. The company currently serves customers primarily in Europe, the United States and Japan.
In response to the global transition toward a low-carbon economy and sustainable development, Auto State has adopted “From Energy Saving to Sustainability” as a guiding principle. The company continues to implement energy-saving improvements across its production equipment, energy management systems, automation technologies and renewable energy facilities.

By installing digital power meters and energy monitoring systems, Auto State can track electricity consumption in different areas of its facilities in real time. This enables the company to identify previously overlooked sources of energy consumption, such as equipment left on standby overnight, idle machinery and compressed-air pipeline leaks.
At the same time, Auto State has been gradually replacing energy-intensive equipment with more efficient alternatives. These include a high-efficiency factory cooling system, five-axis CNC machines, and intelligent automated machining systems. These upgrades have increased production efficiency while reducing unnecessary energy consumption.

Auto State has also installed a 297 kW solar power system, which generates nearly 300,000 kWh of renewable electricity annually. This allows energy conservation and renewable energy generation to advance in parallel.
Over the past three years, various departments have proposed and implemented 12 energy-saving improvement projects. As a result, energy conservation is no longer the responsibility of a single department but has become an integral part of the company’s daily operations and production management. Through these efforts, Auto State is steadily progressing toward its goals of low-carbon manufacturing and sustainable operations.

Introducing the Mazak MPP Multi-Pallet System to Enable Lights-Out Manufacturing

To meet the demands of high-mix, low-volume production, Auto State introduced the Mazak MPP (Multi Pallet Pool), a five-axis automated multi-pallet machining system.
Equipped with a large-capacity tool magazine and multiple pallets, the system reduces the time required for repeated tool changes, machine setup, and equipment standby. It also improves production scheduling flexibility and machining efficiency.

By taking advantage of the system’s automation capabilities, machining operations can continue during unmanned nighttime hours, bringing the company closer to realizing a lights-out manufacturing model.
This improvement saves approximately 4,800 kWh of electricity annually.

Optimizing Automated Warehouse Logistics to Reduce Energy Consumption

Auto State reviewed the material turnover frequency and transportation routes within its automated storage and retrieval system. Based on the results, 600 high-turnover storage locations were relocated closer to the exit area, shortening trolley travel distances and material handling times.

By reorganizing storage locations and optimizing motor start-stop frequency, the company has improved warehouse efficiency while reducing the energy required to operate the system. These measures have resulted in an overall electricity saving of 15%.

Integrating Processes with Multi-Functional Machining Equipment

Auto State is also gradually replacing energy-intensive, single-purpose conventional equipment with two multi-functional machining systems capable of performing several processes, including milling, drilling, chamfering, and groove cutting.

By integrating multiple processes into a single machine, the company has reduced the time and energy consumed when transferring workpieces between machines. It has also minimized losses associated with tooling changes, equipment standby, and waiting for materials, while improving machining accuracy and production efficiency.
This improvement saves approximately 10,000 kWh of electricity annually.

Replacing Energy-Intensive Air-Conditioning Equipment

For its factory air-conditioning system, Auto State completely replaced its conventional air-conditioning equipment with a more energy-efficient cooling system.

Following the installation of the new system, overall energy efficiency improved by approximately 23%. The system maintains the environmental conditions required for factory operations and production while reducing the electricity consumed by air-conditioning equipment.
This improvement saves approximately 23,000 kWh of electricity annually.

Improving Compressed-Air Systems to Reduce Leakage and Standby Losses

Compressed-air systems are among the most important energy-consuming systems in manufacturing facilities. Auto State replaced its conventional piston air compressors with more efficient variable-frequency screw air compressors. The company also conducted a comprehensive inspection and improvement program for its compressed-air pipelines.

Over a six-month period, the project team inspected pipeline joints and valves throughout the factory, area by area. Bubble testing was used to identify leaks, and the results were cross-checked against nighttime compressor operating hours to ensure that the pipelines in all areas remained in good condition.

As part of its daily management practices, operators also close the relevant isolation valves whenever equipment is shut down. This reduces the risk of leakage and prevents unnecessary energy consumption.
Through equipment replacement and improved pipeline management, the company saves approximately 6,000 kWh of electricity annually.

Implementing ISO 50001 to Build a Company-Wide Energy Management Culture

As part of its implementation of the ISO 50001 energy management system, Auto State has encouraged employees across the organization to submit energy-saving improvement proposals. This approach ensures that energy management is embedded not only at the system level but also in the daily activities of every department.

Digital power meters and energy monitoring systems enable the company to track the electricity consumption of individual machines and operational areas in real time. When abnormal electricity consumption is detected, the system automatically issues an alert. The relevant personnel can then initiate appropriate response procedures, address the abnormality at an early stage, and prevent further energy waste.

Through equipment upgrades, smart manufacturing technologies, real-time energy monitoring, renewable energy installations, and company-wide employee participation, Auto State continues to integrate energy-saving principles into its business operations.
Looking ahead, the company will adopt increasingly refined energy management practices to improve production efficiency, reduce carbon emissions, and continue its transition toward low-carbon manufacturing and sustainable development.

Auto State is strengthening its energy performance, contributing to higher industry standards, and advancing steadily toward a more sustainable future.