DECREASING ENERGY INTENSITY IN MANUFACTURING
Assessing the Strategies and Future Directions of the Industrial Technologies Program
THE NATIONAL ACADEMIES PRESS
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NOTICE: The project that is the subject of this report was approved by the Governing Board of the National Research Council, whose members are drawn from the councils of the National Academy of Sciences, the National Academy of Engineering, and the Institute of Medicine. The members of the committee responsible for the report were chosen for their special competences and with regard for appropriate balance.
This study was supported by Contract No. DE-AT01–04EE650009 between the National Academy of Sciences and the U.S. Department of Energy. Any opinions, findings, conclusions, or recommendations expressed in this publication are those of the author(s) and do not necessarily reflect the views of the organizations or agencies that provided support for the project.
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COMMITTEE FOR REVIEW OF THE DEPARTMENT OF ENERGY’S INDUSTRIAL TECHNOLOGIES PROGRAM
JOSEPH G.WIRTH, Chair,
Mount Shasta, California
University of Alabama, Tuscaloosa
Alfred University, Alfred, New York
Reaction Engineering International, Salt Lake City, Utah
General Dynamics Land Systems, Sterling Heights, Michigan
University of California, Davis
WARREN H.HUNT, JR.,
Aluminum Consultants Group, Inc., Murrysville, Pennsylvania
Ajax Magnethermic TOCCO, Madison Heights, Michigan
Kansas State University, Manhattan
Potomac Services International, Inc., Harwood, Maryland
Eastman Chemical Company, Kingsport, Tennessee
Materials Modification, Inc., Fairfax, Virginia
Pennsylvania State University, University Park
Montana Tech of the University of Montana, Butte
BONNIE A.SCARBOROUGH, Program Officer
MARTA VORNBROCK, Research Assistant
BOARD ON MANUFACTURING AND ENGINEERING DESIGN
PAMELA A.DREW, Chair,
The Boeing Company, Seattle, Washington
Sandia National Laboratories, Albuquerque, New Mexico
Wayne State University, Detroit, Michigan
AFL-CIO, Washington, D.C.
Massachusetts Institute of Technology, Cambridge
ROBERT E.FONTANA, JR.,
Hitachi Global Storage Technologies, San Jose, California
Intellectual Assets, Inc., Saratoga, California
Oshkosh Truck Corporation, Oshkosh, Wisconsin
Carnegie Mellon University, Pittsburgh, Pennsylvania
University of Wisconsin, Milwaukee
Robert C. Byrd Institute for Flexible Manufacturing, South Charleston, West Virginia
National Center for Manufacturing Sciences, Ann Arbor, Michigan
Rochester Institute of Technology, Rochester, New York
ANGELO M.NINIVAGGI, JR.,
Plexus Corporation, Nampa, Idaho
PPG Industries, Allison Park, Pennsylvania
Dow Corning Corporation, Midland, Michigan
Rockwell Collins, Cedar Rapids, Iowa
Extrude Hone Corporation, Irwin, Pennsylvania
JAMES B.RICE, JR.,
Massachusetts Institute of Technology, Cambridge
ALFONSO VELOSA III,
Gartner Consulting, Tucson, Arizona
Virginia Polytechnic Institute and State University, Blacksburg
Altarum, Ann Arbor, Michigan
TONI G.MARÉCHAUX, Director
For more than a decade, the Department of Energy (DOE) has supported the Industrial Technologies Program (ITP) as one element in achieving its overall mission and goals. The mission of the ITP is to decrease energy intensity in the U.S. industrial sector through a coordinated program of research and development, validation, and dissemination of energy efficiency technologies and operating practices. At the request of the DOE’s Office of Energy Efficiency and Renewable Energy, the National Research Council (NRC) established the Committee for Review of the Department of Energy’s Industrial Technologies Program. Committee members were selected from industry, academia, and government laboratories for their knowledge and experience with the Industries of the Future and supporting areas within the ITP. An overall review of the ITP was conducted by the committee on May 19–21, 2004, with ITP managers in Washington, D.C. Information from that review forms the primary basis for this report.
The committee was tasked to do the following:
Evaluate the overall ITP strategic plan as contained in the Multi-Year Program Plan (MYPP), including whether the strategic plan is appropriate, has reasonable and achievable goals, and reflects the needs of the DOE and the broader U.S. industrial community;
Evaluate the technical quality and appropriateness of individual subprogram plans by reviewing both the decision-making process and each prospective portfolio, including the following: how focus areas and barriers were identified; whether appropriate data sources were used; whether the data used (studies, roadmaps, industry expertise) support the selection of focus areas and barriers; whether the focus areas and barriers are the highest priority or most appropriate related to the ITP’s mission; how the R&D pathways were determined and whether these pathways are likely to result in achieving program goals; whether the prospective subprogram portfolios are the right ones to achieve the goals of the ITP; whether there are unnecessary research areas or gaps in research; and whether there is a reasonable mix of near-, mid-, and far-term research; and
Determine the prospective value of the MYPP and planning processes, including the likelihood that the program will achieve its goals; whether there is a good plan to carry out the program; how well the program is connected to the users, including non-ITP researchers; and the capacity to develop lessons learned for future interdisciplinary research activities.
This report contains the committee’s assessment of the ITP strategy, how effectively it is being implemented, and the likelihood of achieving its program goals. It includes the committee’s conclusions
concerning the ITP and its subprograms, as well as recommendations on how to strengthen the overall program and improve each of the subprogram areas.
I wish to thank the committee members for their enthusiasm, dedication, and insights in conducting the reviews and in preparing this report. The committee operated under the auspices of the NRC Board on Manufacturing and Engineering Design and was ably assisted by Bonnie Scarborough and Marta Vornbrock of the NRC staff, for which the committee is also grateful.
Questions or comments should be directed by e-mail to firstname.lastname@example.org or by fax to the BMED at (202) 334–3718.
Joseph G.Wirth, Chair
Committee for Review of the Department of Energy’s Industrial Technologies Program
The Committee for Review of the Department of Energy’s Industrial Technologies Program extends its thanks to the following individuals for their considerable efforts in sourcing, consolidating, and presenting so much information: Jordan Blackman, Technology and Management Services, Inc.; J.Michael Canty, Industrial Technologies Program (ITP), Department of Energy (DOE); Isaac Chan, ITP, DOE; Sara Dillich, ITP, DOE; Simon Friedrich, ITP, DOE; Buddy Garland, ITP, DOE; Robert Gemmer, ITP, DOE; David Godfrey, Atlanta Regional Office, DOE; Ehr-Ping HuangFu, ITP, DOE; Ramesh Jain, ITP, DOE; Elliott Levine, ITP, DOE; Dickson Ozokwelu, ITP, DOE; James Quinn, ITP, DOE; Scott Richlen, ITP, DOE; Thomas Robinson, ITP, DOE; Peter Salmon-Cox, ITP, DOE; Paul Scheihing, ITP, DOE; Brian Valentine, ITP, DOE; Gideon Varga, ITP, DOE; and Harvey Wong, ITP, DOE.
This report has been reviewed in draft form by individuals chosen for their diverse perspectives and technical expertise, in accordance with procedures approved by the National Research Council’s (NRC’s) Report Review Committee. The purpose of this independent review is to provide candid and critical comments that will assist the institution in making its published report as sound as possible and to ensure that the report meets institutional standards for objectivity, evidence, and responsiveness to the study charge. The review comments and draft manuscript remain confidential to protect the integrity of the deliberative process. We wish to thank the following individuals for their review of this report: Daniel Berg, Rensselaer Polytechnic Institute; Geoffrey Boothroyd, Boothroyd Dewhurst, Inc.; William F. Brinkman, Princeton University; Robert H.Doremus, Rensselaer Polytechnic Institute; Neil E.Paton, Liquidmetal Technologies; Bhakta B.Rath, U.S. Department of the Navy; Herman M.Reininga, Rockwell Collins; and Peter A.Thorn, Weyerhaeuser Company.
Although the reviewers listed above have provided many constructive comments and suggestions, they were not asked to endorse the conclusions or recommendations, nor did they see the final draft of the report before its release. The review of this report was overseen by Robert A.Frosch, Harvard University. Appointed by the NRC, he was responsible for making certain that an independent examination of this report was carried out in accordance with institutional procedures and that all review comments were carefully considered. Responsibility for the final content of this report rests entirely with the authoring committee and the institution.