The Industrial Assessment Center Procedure

Pre-Visit Procedure

Prior to a site visit, the IAC team confirms that the facility is eligible for IAC services by obtaining and reviewing the plant's four-digit SIC code, number of employees, and annual sales. Several pieces of information are requested from plant personnel including the plant's layout drawing or blueprint, operating hours, shift information, building construction and characteristics, plant environment control, and any available list of major energy consuming equipment. The plant is requested to supply utility bills covering a year of service. This data is analyzed in advance of the IAC's plant visit.

Introductory Discussion

Once a plant has been selected for an Industrial Assessment, and the preliminary information has been obtained and analyzed, the next step is to conduct the actual site visit.

First the IAC team provides a brief description of the assessment process and information about the IAC program. The preliminary information is verified and the graphs of energy cost and consumption are shown. Plant representatives are then asked to discuss plant operations, process equipment, and various other energy-related matters. Also discussed are water and waste costs, and other concerns that were identified in the pre-assessment analysis.

Plant Tour

Following the initial meeting with plant personnel, the IAC team conducts a plant tour to better understand energy consumption and to determine the flow of materials through the plant. The IAC team notes specific operations or equipment identified during the tour which may have possible energy or waste saving potential.

Information and Data Gathering

Following the plant tour, the IAC team discusses areas of potential savings which have been identified, and uses measuring equipment to record pertinent quantitative information about plant equipment. Further discussions with the appropriate plant personnel may take place.

Assessment Review and Recommendation Procedure

After the measurements have been completed, the IAC team meets to compile data, perform elementary analyses, and prepare preliminary recommendations based on the information collected. The focus of the Assessment Recommendations is to improve the plant's manufacturing processes, operations, and waste management. Equipment modifications and replacements are considered, as well as potential changes in the plant operating schedule, or operational procedures.

Post-Visit Procedure

After the IAC team has thoroughly analyzed and evaluated the plant's operation and process equipment, additional suggestions for improvements may be made. The IAC team also conducts research after the site visit, to identify technological products or processes that could help make the plant's operation more efficient and cost-effective.

Final Report

The IAC team finally prepares a formal, final written report to be sent to the manufacturing company within two months of the site visit. The report contains a description of the plant's operation, equipment, energy costs, consumption patterns, and assessment recommendations together with detailed economic evaluations. A copy of the final report, without the plant's identification information, is also sent to the Office of Industrial Productivity and Energy Assessment at Rutgers, the State University of New Jersey for their review, suggestions, and final approval. Non-proprietary data from the form is then entered into the United States Department of Energy Database.

Follow-Up Procedure

About six months after the final report is sent to the company, a final follow up is conducted to determine which recommendations were ultimately implemented, which are still under consideration, and the reasons for not implementing the remaining recommendations. For recommendations that were implemented, plant representatives are asked to provide implementation costs, projected savings, and actual savings to date. Information on what recommendations have been implemented and the cost and energy savings are compiled and included in the Department of Energy Database.