A smart factory is deemed efficient when it controls its energy consumption. Energy is vital for a factory, as its production and maintenance completely depend on electricity, water, and gas. However, unnecessary energy consumption can lead to budgeting issues and increased production costs. Hence, comprehensive energy management system software should be deployed to minimise excessive costs.
Key Components of Energy Management Systems
Energy management software are data-driven systems that display real-time information about your factory’s energy consumption. You can view your energy usage in all its forms on one dashboard. Basically, there is no need to work on separate sheets and data channels to calculate energy consumption. A few simple clicks and the right navigation system will showcase all your energy-related data. Here are the key components of a smart energy management system that form a holistic energy analysis and management facility.
Sensors and Data Acquisition
Sensors are attached to the devices and energy channels. They measure each device’s energy consumption and compare it to optimal levels. These sensors are also very sensitive to minor changes in the consumption pattern. Hence, their acute detection capabilities let you watch for any untoward impairments in the system.
Data Analytics and Visualisation
Sensors and their associated systems have real-time data analysis features. You don’t need to perform a set of calculations separately for each metric. The data and its analysis are readily available in the system. Moreover, systems integrated with artificial intelligence provide precise and nuanced insights about energy consumption. You can view the following metrics in an energy management software system:
- Consumption costs per machine
- Unproductive energy consumption
- Defects in the machines
- Overall energy consumption of the factory
- Insights on saved energy consumption
- Monthly data and reports
Energy Control and Optimisation
Data drives decisions and often results in profitable outcomes. Therefore, using the above data to optimise your energy consumption will lead to more savings. You can track the performance of all equipment and take appropriate actions to correct faults. This strategy will lead to efficient energy consumption and increase the lifespan of the equipment.
Integration with other Factory Systems
The smart energy management software system integrates with managerial systems like SCADA and MES. You will have a robust and comprehensive solution to all your energy management needs. Moreover, you can also gauge the total energy efficiency of your factory’s processes as a whole by considering energy consumption from the following costs:
- Production Costs
- Overhead Expenses
- Indirect Costs
- Utility Costs
These versatile components benefit factories that adopt the energy management system. These benefits will be amplified in the long term and prove advantageous for an energy-efficient future.
Benefits of Energy Management Systems in Smart Factories
Although energy management system software offers numerous benefits, these four are extremely impactful. The cumulative benefits of the advantages mentioned below are simply cost and time savings. An experienced manufacturer will know the value of these two resources in a smart factory’s operations.
Cost Reduction
EMS will reduce your unproductive energy costs by sheer detection and data analysis. You can optimise your processes to consume less energy and provide similar productivity. Therefore, you will significantly reduce your downtime and energy consumption, which can be allocated to produce more valuable products.
Increased Efficiency
Efficient energy management also leads to a better working environment. These systems allow you to conduct energy audits and benchmark reporting to monitor your energy usage regularly. Intelligent insights from the system will reduce waste and help you achieve your sustainability goals.
Corporate Social Responsibility
CSR activities showcase your commitment to society and your ethical values. Such activities contribute to a better world for everyone. Therefore, reducing energy consumption will enhance your CSR credentials and positively impact your market reputation.
Improved Decision-making
The valuable data provided by EMS leads to informed decision-making. The dashboard’s enriching reports and visualisations can help you make accurate decisions. You will also be more adaptable to change and quickly act through escalations and alerts.
Potential Challenges
Adapting new energy management systems can present a few challenges. Fortunately, identifying these challenges beforehand can help you plan your next course of action.
- High upfront costs: The initial investment in the services can be very high.
- Complexity and integration: EMS is complex to implement, so integrating it with existing factory systems can be challenging.
- Resistance to change: Employees may resist changes to their work processes and routines.
- Data quality and accuracy: Accurate and reliable data collection might be hampered during system errors.
Tips for Overcoming Challenges
These tips will help you effortlessly overcome these challenges. However, you must incorporate these solutions with assistance from a good vendor.
- Conduct an Assessment: Identify your factory’s energy-saving opportunities and challenges.
- Develop an Implementation Plan: Outline your energy-saving solutions’ steps, timelines, and responsibilities.
- Invest in Training: Train employees to use EMS.
- Scale gradually: Test a pilot project to check the feasibility of EMS before implementation.
- Address Concerns: Actively address employee concerns and provide support to.
- Seek Expert Guidance: Consult with energy management experts.
- Monitor Performance: Continuously monitor the performance of EMS and make necessary adjustments.
- Leverage technology: Integrate advanced technologies like AI and IoT to simplify EMS data analysis.
- Foster a Culture of Energy Efficiency: Create a company-wide culture that values energy conservation and sustainability.
A smart energy management system is crucial in optimising energy consumption and improving efficiency in smart factories. EMS helps factories reduce costs and enhance decision-making. The long-term benefits of energy savings and improved sustainability make it a worthwhile investment for smart factories. You will achieve your profitability goals with a tailored energy management solution! PowerCONNECT is one such solution. It is our cutting-edge energy management system will optimise your energy consumption, reduce costs, and enhance sustainability.