The smart factory is by nature energy-efficient, as it optimizes its performance thanks to precise knowledge of its needs based on metering data. The good news is that the analysis of this data is at the heart of the intelligent energy management approach, and can be implemented without the need for a substantial budget for metering equipment or ISO 50001 certification.
Here are a few tips for laying the foundations of an Energy Management System while limiting investment and generating initial energy savings: a few measuring points at the supplier delivery point, upstream of a workshop or a group of machines may be enough to ask the right questions without waiting for the bill: what is the plant's daily consumption, in MWh and in euros? Where and when does the plant consume more energy?
Example: flow meters, ERP, CMMS, CAPM, TRS, etc. They can be used to find out more about machines that are not equipped with meters. These data are often already accessible and available, and can be automatically compared with data from energy meters to find out more: start-ups and shutdowns, exceptional peaks, etc.
This knowledge can also serve as a performance benchmark. The cross-analysis of these data provides an initial assessment of the situation, enabling actual consumption to be compared with expected consumption, and quantifying the past and future cost of consumption anomalies: kWh/t of product manufactured, energy costs linked to breakdowns, etc.
This is a relatively short period: less than 6 months. It enables the first savings to be achieved, mobilizing the operational teams around an initial success: lower temperatures or compressed air flows, peak shaving, reduced downtime, reorganization of planning, etc.
These savings will then be used to roll out a training plan, install or revamp new smart meters to complete the metering plan, or begin the ISO 50001 certification process for an initial scope.
What practical advice would you give to a manufacturer who wants to get started on a smart factory process?
