This paper prescribes an energy assessment methodology, including the procedure and mathematical foundation for evaluating total use and efficiency, for mechanical and electrical product assembly processes. The majority of major manufacturers assemble components and subsystems often produced by suppliers in their supply chains. Differing measurement processes of resource use in product assembly processes yield discrepant resource use assessments. We developed a sequence of activities, including goal setting, defining baselines, measurement, analysis, reporting, evaluation, and resetting the goal for product assembly processes. These activities are to be pursued in an iterative process leading to incremental improvements towards achieving sustainable manufacturing. An application example of reflow soldering was used for verification of the proposed new process’ representativeness and completeness. This methodology provides a guideline for manufacturers to make sound decisions that can be tightly integrated with their business strategy.

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