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training experience of both IAC and SME students; enhance the conduct of the assessments by incorporating more process improvement recommendations; and lastly, to increase the implementation rate of energy saving recommendations made by the IACs. Because of their focus on manufacturing processes, SME students are ideally suited to collaborate with facility management to construct a business case for making the necessary investments to implement energy efficiency and process improvements. Additional benefits include: • Promoting SME and IAC students to develop senior de- sign capstone projects or graduate-level research projects based on follow-up efforts with manufacturers;


• •


Increasing opportunities for reverse internships (e.g., util- ity employees and others spend time with the IACs);


Creating affiliations for the IACs with other professional societies that also work with SME (ASME);


• Encouraging IAC students to join SME; • Encouraging SME student chapter members to look at IAC employment opportunities;


Students on an IAC assessment confirm Energy Use Readings associated with an industrial pumping system.


survey of the eligible plant, followed by a one- or two-day site visit in which the team takes engineering measurements as a basis for assessment recommendations. Te team then per- forms a detailed analysis for specific recommendations with related estimates of costs, performance and payback times. Within 60 days, a confidential report, detailing the analysis, findings and recommendations of the team is sent to the plant. In six to nine months, the team lead follows up with the plant manager to verify recommendations that have or will be implemented. Overall savings calculations are determined by adding the estimated savings values for each of the imple- mented recommendations.


Assessment Results Since 2010, the IACs have conducted between 300–400 as-


sessments per year. On average, each manufacturer identified about $140,000 in potential annual energy savings and imple- mented more than one-third of these within the first year of the assessment. Te average payback period for recommenda- tions that were implemented following an IAC assessment was 1.2 years. Since 1981, over 16,000 IAC assessments have resulted in nearly $5.9 billion in energy savings and close to 28 million metric tons in CO2 emissions reductions.


IAC/SME Collaboration Beginning in 2013, the US Department of Energy an-


nounced a five-year collaboration between the IACs and SME. Te objectives of this collaboration are to enhance the


86 Energy Manufacturing 2014 •


Creating possible affiliations with Manufacturing Exten- sion Partnership and SME student chapters;


• Providing additional resources to small and medium- sized manufacturers through SME, without additional infrastructure at the Energy Department (e.g., direct links to SME Education Foundation, SME Technical Commu- nity Networks, Manufacturing Education and Research, Lean to Green); and


• Expanding the number of industry partners reached by the IAC program. As the collaboration just completed its first year, the


On average, each


manufacturer identified about $140,000 in potential annual energy savings and implemented more than a third within the first year.


results were limited to a subset of pilot schools. Nonetheless, three IACs (Oregon State, Tennessee Tech, and UMass) have completed a total of 11 joint assessments addressing both energy efficiency and productivity-related improvement op- portunities. On average, the value of identified opportunities exceeded $160,000 per assessment. Both SME and the IACs anticipate significantly expanding the scope of this innovative collaboration during the coming year.


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