Manufacturing execution systems have revolutionised factory management. The technology is an innovation on its own. However, with further advancements in this technology, efficiency and productivity have increased. Manufacturing execution system vendors are integrating their systems with new technologies for faster turnarounds. Companies that have adopted these systems say they provide better management and assistance than ever before.
The same goes for smart energy management systems. The trends showcase that companies rely on this technology to meet their sustainability goals and optimise their energy consumption. Let’s look at these trends to understand how these new technologies work.
Manufacturing Execution Systems (MES) Trends
Digital Twin Integration
A digital twin is a virtual visualisation of a real product or process that may be utilised with an MES. It is a virtual depiction of an actual product or process, enabling real-time visibility and control over manufacturing operations. MES may gather and analyse data, monitor production activities, and deliver performance, status, and quality reports.
Artificial Intelligence and Machine Learning
Integrating generative AI into MES will increase predictive maintenance, resource allocation, and product quality. However, it primarily aids shop floor operators and managers in making choices and managing production processes using data expertise. For example, in the fashion industry, accuracy and compliance are critical. AI will assist operators in running safer, more dependable manufacturing processes, lowering production irregularities and eliminating risks. This will be especially beneficial in overcoming the workforce’s lack of expertise when older, more experienced workers retire in growing numbers.
Internet of Things
IoT and edge computing provide real-time monitoring and control of manufacturing operations. In the FMCG business, this can result in better inventory management, faster market reaction times, and greater product monitoring across the supply chain. All of these factors contribute to high levels of quality control and customer satisfaction. For instance, Prescient’s factoryCONNECT uses IoT to monitor and optimise supply chains. Companies testify that its sensors have significantly reduced the downtime of the production line and increased its output.
Cloud-Based MES
Cloud-based MES helps enterprises streamline production to meet market demand and offer new goods more quickly. It is more cost-effective and feasible for manufacturers since it eliminates the need for physical equipment and additional IT personnel. Cloud-based MES enables firms to connect departments and include customers and subcontractors in the supply chain. It also assists manufacturers in enabling AI, Digital Twins, and Machine Learning to enhance visibility, analysis, and collaboration.
Cybersecurity
Manufacturing execution system vendors are performing the following operations to secure your data:
- Use a powerful encryption method, such as AES (Advanced Encryption Standard), to safeguard data in transit and at rest.
- Use tight access restrictions and multifactor authentication to prevent unwanted access.
- Ensure that MES software is regularly updated and patched.
- Monitor network traffic with firewalls and intrusion detection systems to identify possible dangers.
Smart Energy Management (SEM) Trends
Energy Efficiency
Smart energy management systems have in-built audit tools that provide automated reports. These reports help in aligning business processes with smart energy goals. The technology aims to democratise energy efficiency and transparency across the organisation, making it crucial for optimisation.
Renewable Energy Integration
Renewable energy integration refers to linking renewable energy sources to the electrical grid. It entails generating, transmitting, and distributing renewable energy into the conventional power grid. Solar, wind, and storage systems can be installed in distant places or isolated from the main grid during outages. New standards and guidelines are created to link more dispersed energy systems. Machine learning algorithms examine big datasets to anticipate renewable energy power outputs. These methods will help promote renewable energy use.
Demand-side management (DSM)
Demand Side Management refers to a range of tactics used by SEM providers to reduce energy consumption. SEM provides time-of-use or peak-load pricing to encourage companies to save energy during peak hours. It allows companies to get monetary incentives as they can now purchase energy-efficient equipment or lower their energy use during peak hours. With this system, companies can install energy-saving devices such as LED lights, smart thermostats, and high-efficiency chargers for better energy efficiency.
Smart Grid Integration
Smart grids track power flow from generation to consumption in real time. They can even monitor power usage at the appliance level. They optimise energy efficiency in the following ways:
- Manage electricity flow and reduce the load in real-time to match generation levels.
- Offer two-way communication between customers and utilities.
- Renewable energy sources like solar and wind power should be included in the system.
- Collect information about energy use and consumer preferences.
- Utilise cybersecurity methods like encryption and threat detection to defend themselves from cyber threats.
Energy Analytics
Energy analytics give a picture of previously unattainable insights into a company’s energy statistics. Energy analytics software shows when the highest energy spend occurs. It also identifies which aspects of the company are inefficient and how external variables affect energy use. For example, Prescient’s PowerConnect has energy data analytics that reveal if one of your buildings consumes a surprising amount of energy during non-operational hours. Further examination may reveal that the heating controls in this building are malfunctioning. Taking action and resolving this issue will save thousands over a year.
MES and SEM technologies are rapidly evolving. Manufacturers can optimise their operations and improve sustainability by adopting these systems. They can gain all the benefits of the new advancements with a fully-fledged smart energy management and manufacturing execution system integration.
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