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Energy loss matrix template
An energy loss matrix is a grid that puts a cost on every kind of energy waste on a site, so you can see which few cells hold most of the money. Down the side are seven loss types in plain words: idle consumption, over-consumption, poor settings and sequencing, unrecovered energy, leaks and transmission losses, inefficient technology and energy source choice. Across the top are the energy sources: electricity, gas, compressed air, steam and hot water, heating and cooling, and water. Each cell holds the yearly cost of that loss. The template has five landscape pages: the matrix, an action plan that turns the largest cells into actions with a saving, an idle-period shutdown checklist that works out the saving from load, hours and price, and a worked example of a made-up plastics plant in which two cells hold 55% of a $210,000 yearly loss. The Excel version adds totals, shares, a colour scale, an action plan whose cost is looked up from the matrix, a summary with a chart, and the shutdown checklist with its saving. It goes further than an energy use tracker, which records consumption but not the loss, and it uses the same cost logic as a loss tree.
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
A grid with seven loss types down the side and six energy sources across, with an empty cell for the yearly cost of each, a total column and a total row.Seven loss types by six sourcesTotals and sharesAction plan with savingsIdle-period shutdown checklistSummary and chartWorked example
When to use it
When to use an energy loss matrix
- When an energy bill is rising or has to be cut and nobody can say which losses matter most.
- To start an energy saving programme with a ranked list of actions rather than a long list of ideas.
- After an energy audit or a leak survey, to turn findings into costs and actions with owners.
- To find the cheap wins: equipment left on at breaks, shift ends and weekends.
- Not for tracking monthly consumption against a baseline (use an energy use tracker) or for a single leak survey (use a compressed air leak log).
How to fill it in
- 1
Set the boundary and the energy sources
Decide which site, area or line you are looking at and which sources are on the bill: electricity, gas, compressed air, steam and hot water, heating and cooling, water. Use one currency and one year.
- 2
Cost each energy source
Take the yearly cost of each source from bills or meters. Where there is no meter, estimate from equipment ratings and hours, and mark the cell as an estimate.
- 3
Split each source by loss type
For each source, estimate how much is lost as idle consumption, over-consumption, poor settings, unrecovered energy, leaks, inefficient technology or a poor choice of source. The cells for one source add up to its waste, not its whole bill.
- 4
Find the largest cells
Shade the two or three cells that hold the most money. A grid with a colour scale makes them stand out. These are the first actions, not the long tail.
- 5
Write an action for each large cell
Say what you will do, who owns it, when, and what share of the cost you expect to remove. Use the shutdown checklist for equipment that is idle at breaks, shift ends and weekends.
- 6
Measure and update
Count a saving only after the meter or the bill shows it. Update the matrix each quarter: a cell that has been fixed shrinks and a new one takes its place.
A filled-in example
Illustrative, not a benchmarkAn example: a made-up plastics plant with an estimated yearly energy loss of $210,000. The costs are invented.
- The largest loss type is leaks and transmission losses at $83,000, followed by idle consumption at $69,000. Together they are $152,000, or 72% of the loss.
- The two largest cells are compressed air leaks at $76,000 and weekend heating and cooling at $39,500. Together they hold $115,500, which is 55% of the loss.
- The actions are a quarterly leak survey and repair, a weekend set-back on the building controller, a weekend shutdown checklist for heaters and chillers, an efficient drive study and a heat recovery study.
- The five actions would save about $95,900 a year, 46% of the loss, and four pieces of equipment on the weekend shutdown checklist add $13,552 of electricity saving from a switch-off.
A long list of ideas became two actions to start this month. The numbers, owners and equipment are invented to show how the matrix works.
Common mistakes
Costing only electricity
Compressed air, steam, gas, heating and cooling and water often hide the largest losses. Put every source on the grid, even if some cells are estimates.
Mixing the loss types
A leak is not over-consumption and an idle machine is not a poor setting. Keep the types separate, because each has a different fix.
Starting with the easiest cell
Lighting is easy and small. Start with the cells that hold the most money, and take the cheap wins alongside them.
Counting a saving before it is measured
A planned saving is a forecast. Check the meter or the bill after the action and record what was actually saved.
Making it a one-off
Leaks come back and equipment is left on again. Update the matrix on a schedule and re-run the leak survey and the shutdown checks.
Download the template
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Run this template in LeanSuite
LeanSuite's Loss and Cost Management imports your loss data, shows a loss tree that puts a cost on each loss, and tracks the savings as you remove them.
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FAQ
Energy loss matrix template: common questions
An energy loss matrix is a grid with types of energy loss down one side and energy sources across the top, with the yearly cost of each loss in each cell. It shows which few cells hold most of the waste so you can act on them first.
This template uses seven: idle consumption, over-consumption, poor settings and sequencing, unrecovered energy, leaks and transmission losses, inefficient technology and energy source choice. They are general categories in plain words. Rename or merge them to suit your site.
An energy audit measures and surveys the site. The matrix is how you organise what the audit finds, by type and source with a cost on each, so the findings turn into a ranked list of actions with owners.
Use equipment ratings, hours of use and the price of the energy, and mark the cell as an estimate. Then add a meter where the estimate suggests a large cell, because the next version of the matrix will be better for it.
Often, because the fix is a switch-off, a timer or a set-back, not a purchase. Check first that nothing has to stay on for safety, quality or a restart that costs more than it saves. The shutdown checklist records who does what and when.
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- Professional maintenance (PM) 90-day model area planThirteen weeks from breakdown analysis to a running PM calendar on one model machine, a KPI board, the day-90 gate and expansion waves.
- Focused improvement 90-day model area planThirteen weeks from the loss Pareto to standardized fixes on one model line, a KPI board, the day-90 gate and expansion waves.
- Logistics and customer service pillar 90-day model area planThirteen weeks from the current-state map to pull on one model value stream, a KPI board, the day-90 gate and expansion waves.
- People development pillar 90-day model area planThirteen weeks from the skills matrix to trained cover on critical tasks in one model area, a KPI board, the day-90 gate and expansion waves.
- Early equipment management 90-day model area planThirteen weeks from lessons on current machines to a tracked start-up on one model equipment project, a KPI board, the day-90 gate and expansion waves.
- Moving from Excel to one system checklistA 34-point checklist and a file inventory for moving trackers from spreadsheets to one system: keep, move, connect or retire, clean, pilot, run both, retire.
- Prioritization matrix templateScore up to 20 improvement ideas on weighted criteria, rank them, test the ranking with equal weights and place each one on an effort and benefit grid.
- Digital manufacturing readiness assessmentScore 24 statements on process, technology and people from 0 to 4, check the balance between them and rank the gaps by what matters in your plant.
- Manufacturing KPI dashboard templateWeekly plant numbers in, 14 KPIs out: OEE and its parts, first pass yield, scrap, on-time delivery, recordable rate, cost and absence, each against a target.
- RCM worksheet (failure mode and task selection)Failure modes classed as hidden, safety, operational or non-operational, then a task chosen for each: condition-based, discard, failure-finding, redesign or run to failure.
- Error-proofing verification log (daily master-sample check)Each poka-yoke device proved every day or week with a known-bad sample, with missed checks counted and the hours and parts at risk worked out when one fails.
- Training matrix template with expiry datesPeople by required trainings with expiry dates, OK, due, expired and missing flags, compliance by person and area, cover per training and a renewal list.
- Downtime reason codes template26 starter codes mapped to the six big losses, a log with drop-downs, a Pareto by code and by loss, and a code card for the line.
- Defect catalogue template with boundary samplesEvery defect with a definition, a class and the reason for it, measured accept and reject limits by zone, boundary samples, a defect log with DPU and Pareto, and an inspector agreement check.
- I-MR chart template (individuals and moving range)Up to 100 single readings with moving ranges, limits from a baseline, five run-rule flags, both charts, a second phase and a reaction log.
- Kaizen event preparation checklistEverything that has to be ready before a kaizen event and done after it: 44 items with owners and due dates from 6 weeks before day 1 to 30 days after, five go or no-go gates and a day-by-day agenda.
- Attribute control chart template (p, np, c and u charts)p, np, c and u charts in one workbook: a chart selector, a sample size check, limits for each subgroup, signal flags and four worked examples.
- Critical spare parts list and stocking levelsAssets ranked by consequence, each part classed and given a stocking policy, and min and max worked out from usage and lead time, with the downtime each stock-out would cost.
- Tier 2 meeting agenda and escalation sheetA 15-minute tier 2 agenda in ten timed blocks, fixed roles and rules, escalation triggers with time limits, and a log that ages every escalation and sends the answer back down.
- HACCP plan template: hazard analysis and CCP worksheetThe Codex 12 steps in one workbook: team and product, process steps checked on site, hazard analysis with the CCP decision tree, the CCP table with completeness checks, an allergen matrix and a verification schedule.
- Forklift operator training and evaluation recordPer-operator training and evaluation record, a register with three-year due dates and refresher triggers, and a weighted practical evaluation scoresheet.
- REBA worksheet (Rapid Entire Body Assessment)Score up to six postures with REBA: body-part drop-downs, Tables A, B and C as lookups, final score and action level, and a before and after comparison.
- Mock recall template: traceability exercise worksheetTrace a finished lot back to every input lot and forward to every first customer, reconcile the quantities against a tolerance and time it against your target.
- ISO 9001 internal audit checklist (production area)46 audit questions for the production floor in 11 processes, each with its ISO 9001:2015 clause, what evidence to look for and the sample to take, plus five defined grades, a findings log, a finding report and a summary by clause.
- ISO 45001 internal audit checklist44 audit questions for the plant floor in 16 safety topics, each with its ISO 45001:2018 clause, the evidence to look for and the sample to take, plus 12 worker interview prompts, a findings log and a summary by clause.
- Plan for every part (PFEP) templateOne row per part: supplier, pack, container, usage, lead time and locations, with ABC classes, market and line kanban counts and a lineside space check.
- Food plant GMP inspection checklist (21 CFR 117 subpart B)55 checks in the order of 21 CFR 117 subpart B, each citing its paragraph and saying what to look at, with a grade, finding, owner and due date; results by section and grade, a walk route and a bakery example.
- Master sanitation schedule with pre-op verificationA master list of cleaning tasks by area and equipment with frequency, chemical, lockout, who and next due date, a weekly on-time count, and the pre-operational verification log with a release step.
- Changeover matrix templateA from-to matrix of changeover minutes with the clean each transition needs (allergen, colour, format), and a weekly planner that totals the order and suggests a shorter one.
- Overhead crane inspection checklist: frequent and periodic34 crane checks tied to OSHA 1910.179: an operator's pre-shift card, frequent and periodic inspections with signed records, a deficiency and tag-out log, and a register of next due dates.
- Measurement uncertainty budget templateA GUM uncertainty budget: Type A and B rows, divisors by distribution, sensitivity coefficients, uc, νeff, k from the t-table, U, TUR and a guard band check.
- Maintenance job plan templateOne job planned on one sheet: steps and craft hours, parts checked against stock, tools, lockout and permits, documents, a ready check for the schedule, and technician feedback.
- Video time study filming checklistA pre-shoot checklist and shot log for filming a time study on video: camera, light, people, settings, power and review.
- Reorder point and safety stock sheet (many parts)Safety stock, reorder point, order quantity and an order list for up to 500 parts, worked out from each part's own demand and lead time history.
- OSHA compliance calendar (general industry)37 recurring federal OSHA duties with the paragraph, interval, owner, next due date and an overdue flag, plus a 12-month view and counts by owner.
- TRIR and DART rate trackerMonthly hours, OSHA 300 case counts and near misses in; rolling 12-month TRIR and DART rate, a case budget against your target and a trend chart out.
- FIFO lane sizing sheetThe maximum for a FIFO lane from the stop it must cover, in whole containers, with length, refill and wait checks for up to eight lanes.
- Pugh matrix templateCompare up to 8 concepts with a datum as better, same or worse on up to 12 criteria, flag must-haves, and carry the strongest into a second round.
- Machine guarding inspection sheetA machine register with due dates and a status per machine, 21 checks tied to OSHA 1910.212, .219 and .147, a guard opening check against Table O-10, and an action log.
- Condition monitoring route sheetA route of measuring points with baselines, alert and alarm limits, a check interval from the P-F interval, readings with rising and overdue flags, and an exceptions list worst first.
- Fire extinguisher inspection logOne row for every portable extinguisher: hydro test interval from OSHA Table L-1, annual and 6-year due dates, a 12-month check grid and open issues.
- Quad chart templateA project on one page in four boxes: idea and owner, problem, approach, and cost, schedule and result.
- Toolbox talk topics (52 weekly topics)52 weekly toolbox talk topics, each with a one-line key message and a discussion question, and a tracker for the year.
- Equipment register templateOne row per asset, with hierarchy, criticality, PM strategy and owner, and a check that flags what is missing.
- Machine history record templateOne record per machine: components and their life, every breakdown and repair with cost, MTBF and MTTR, and a repair-or-extend check.
- Defect detection matrix templateMap where each defect is created and where it is found, score the gap and move the check closer to the cause.
- Equipment design review checklistGate reviews for a new machine before order, before build and before start-up, with a safety buy-off and a problems journal.
- Emergency action plan templateA written emergency plan for a plant: site facts, roles and backups, warden coverage, scenario steps and a drill record.
- Preliminary hazard analysis (PHA) worksheetFind and score the hazards of a new line, machine or process before design is fixed, then choose controls and re-score.
- Risk register templateOne scored list of operational risks with owners, actions and dates, a heat map and a review log.
- Hot work permit templateA hot work permit with a precautions checklist, fire watch record and close-out, plus an Excel permit log.
- Confined space entry permit templateA confined space entry permit with checks, an air test log, an entry log and cancellation, plus an Excel register.
- Management safety tour formA leader's scheduled safety walk: observation form, operator interview, tally, actions, rota and a tour log with a dashboard.
- Hazard prediction worksheetA pre-task worksheet: score what could go wrong at each step of a job, add a countermeasure and score again.
- Safety committee meeting minutes templateMinutes for a safety committee: attendance, nine agenda items, an action log that carries open actions forward, and monthly numbers.
- APQP checklistThe five APQP phases as a checklist: deliverables, owners, due dates, gate reviews and an issues list.
- Out-of-control action plan (OCAP) templateA reaction plan for a control chart: the steps, what each signal means, who to call and a log of events.
- Quality inspection checklistAn in-process and final inspection record: measured characteristics, visual checks, a decision and first pass yield.
- AQL sampling plan templatePick a sample size, read accept and reject numbers, record the defects and decide on the lot.
- MSA study workbookBias, linearity and stability study sheets for a gauge, with the arithmetic done and a guide to which study when.
- Incoming quality control stage sheetA register that shows how much control each purchased part has and plans the move from your dock to the supplier's process.
- Internal audit schedule templateA year of internal audits planned by risk: the programme, the register, the auditors and the findings.
- Approved supplier list templateThe list of suppliers you may buy from, with the evidence behind each, certificate expiry alerts and re-evaluation dates.
- Pest control inspection checklistA pest control walk-round for a food plant, with a log of traps and stations and action levels for each type of device.
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A shift handover sheet, a red tag log, a changeover checklist for one machine: if your team uses it on the floor, ask.