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Performing a Smart Energy Management Assessment

Step 1: Pre-Assessment Information Gathering

  1. Size of plant and plant layout
  2. Industry type (SIC / NAICS code) and process description
  3. Production levels, units and dollars, operating hours
  4. One year history of utility bills
  5. List of major energy consuming equipment
  6. ETISE survey on smart manufacturing

Step 2: Ensure that key plant personnel are involved

  1. Plant Manager
  2. Energy Manager
  3. Environmental personnel
  4. Maintenance personnel
  5. IT

Step 3: Pre-Assessment Analysis

  1. Analyze the manufacturing process
  2. Chart and graph utility bills
  3. Analyze utility bills for trends and errors; establish unit cost of energy
  4. Create plant profile using Plant Energy Profiler Tool – Plant Energy Profiler Excel
  5. Identify key energy systems
  6. Review design and other technical documentations
  7. Identify potential smart manufacturing for energy management recommendations
  8. Develop assessment day strategy

Step 4: Day of Assessment

  1. Introduction
  2. Roundtable introductions, intro to ETISE program
    1. Distribute BP tools, case studies, tip sheets
  3. Description of manufacturing process and operations
  1. Is this a typical day?
  2. Run through process following material flow
  3. Discussion of existing IT architecture and energy management process
  4. Questions about defects, bottle necks, data silos, interconnection
  5. Present charts and tables of utility bills
  6. Plant Tour
  1. Conduct in the direction of material flow
  2. Maintenance or floor leader to conduct tour with support from plant manager
  3. Conceptual tour, identify areas for smart manufacturing improvements
  4. Meeting room debriefing
  1. Discuss process, ask questions
  2. Develop plan for afternoon and create specific tasks
  3. Review notes and brainstorm (Working Lunch)
  1. Develop list of potential smart manufacturing and energy management opportunities
  2. Ensure that everyone has clarity of process and potential recommendations
  3. Refine list of opportunities to be investigated
  1. Decide what information needs to be gathered, measured, monitored
  2. Assign specific tasks
  3. Make plan to finish at assigned time and place
  4. Data Gathering
  5. Conduct measurements, monitoring, and diagnostic testing
    • Energy management process
    • Decarbonization
    • ITData practices
    • Building systems
  6. Exit Interview
  1. Discuss findings with management
  2. Preliminary estimate of potential recommendations
  3. Prioritize recommendations

Step 5: Post Assessment Activities

  1. Conduct engineering and financial analysis
    • Develop first order estimates of implementation cost
    • Deliver report to client
  2. Contents of Report
    • Executive summary including summary of recommendations
    • Plant descriptionProcess description
    • Resource charts and tables
    • Major energy consuming equipment
    • Best practices
    • Smart manufacturing recommendations
    • Energy management recommendations
  3. Follow-up to Report
    • Call client two week to ensure report delivery and answer questions
    • Call client in 6-9 months for implementation data