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On Friday, September 25th, Alliance to Save Energy hosted “Smart Manufacturing: Modernization to Marketplace,” in the Rayburn House Office Building. This briefing, moderated by the Alliance’s Vice President of Programs, Jeffery Harris, explored the merits of smart technologies—including sensors and wireless controls—in a modern manufacturing environment. Subject experts, including Mr. John Bernaden of Rockwell Automation, Dr. Peter Fuhr of the Wireless Industrial Networking Alliance (WINA) and Wi-fi Sensors, Inc., and Dr. Thomas Reddoch of the Electric Power Research Institute (EPRI), each shared unique perspectives coupling smart manufacturing with enhanced equipment reliability, process optimization, increased productivity, and energy savings.
Mr. John Bernaden of Rockwell Automation opened the program. Mr. Bernaden underpinned the panel presentations by explaining the basis of industrial process optimization hinges on a robust data set. Industrial data drives decision-making from the plant floor to the front office, be it production schedules, equipment maintenance or process optimization. Today, industrial sensors and wireless controls exist providing real-time data feeds to manufacturing customers, although leveraging promising emerging technologies that may be integrated into existing networks, the picture begins to represent the true vision of a ‘smart-manufacturing facility’. Mr. Bernaden indicated the best ways to promote the development and deployment of capable smart devices are open standards and increased funding of applied research and development. Mr. Bernaden suggested a ‘greenprint’ to guide investment toward green manufacturing. Bernaden underscored his support for applied research noting federal funding for engineering and physical science research R&D has reduced by half since pre-1970 levels.
Dr. Peter Fuhr of the WINA reinforced support for smart devices. Fuhr explained the practicality of wireless devices in a manufacturing setting, citing accessibility and the elimination of wiring as two positives that transcended industrial subsectors. Dr. Fuhr clearly linked smart technologies with energy savings, and cited specific examples from his own manufacturing plant in Kirksville, MO where he initiated a demonstration project to provide a case for sensor adoption. Fuhr went on to trace an upwelling of commercial and industrial wireless activity back to seed funding originating from the U.S. Department of Energy’s (DOE) Industrial Technologies (ITP) program. This example successfully demonstrated the importance of federal support in the deployment of market-shaping technologies.
Dr. Thomas Reddoch of EPRI capped the day’s presentations. Dr. Reddoch positioned smart technologies as critical to managing the industrial sector’s energy use and greenhouse gas (GHG) emissions, and echoed earlier emphasis of the value of manufacturing data. Dr. Reddoch offered one major challenge in industrial energy efficiency—that is, better understanding the energy load shapes of manufacturing equipment. Using smart applications in a manufacturing facility can enable managers to access real-time load data, which is a crucial step in significant energy reductions in manufacturing operations. Dr. Reddoch indicated a strong promise in new smart manufacturing technologies, and pointed to the steep adoption curves of other electronic devices such as television, cell phones, radio, and the internet in support of his projection.
Friday’s program was the third in a series of briefings to take place over the next 12 months. The Alliance to Save Energy, with support from Department of Energy’s Industrial Technologies Program, will be hosting Efficient Enterprises: Powering American Industry, highlighting specific opportunities to enhance energy efficiency in the U.S. industrial sector. This seminar series will emphasize energy efficiency as a key issue underpinning the revitalization of the American economy while easing environmental impacts resulting from industrial operations.
Please contact Paul Bostrom (Pbostrom@ase.org) for general information or to inquire about speaking opportunities.
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