Our life is strongly linked with the usage of natural resources. Energy is a necessity in everyday life and is often generated using non-renewable natural resources which are finite. Energy consumption in manufacturing industry is increasing and the way it is consumed is not sustainable. There is great concern about minimizing consumption of energy in manufacturing industry to sustain the natural carrying capacity of the ecosystem. This is one of the challenges in today’s industrial world.In this paper two case studies have been carried out in crankshaft machining and cylinder head casting processes. The outcome of this research enables the company to identify potential avenues to optimize energy usage and offers a decision support tool.