Manufacturing | Cost & Energy Management
Manufacturing Process and Asset-Level Energy Monitoring
Objective
Manufacturing industries face significant challenges in optimizing energy consumption at both the process and asset levels. Inefficient energy use leads to increased operational costs and environmental impact. A comprehensive solution is needed to monitor and optimize energy usage in real time.
Challenges
- Data Integration: Aggregating data from diverse sources such as sensors, PLCs, and SCADA systems.
- Real-time Monitoring: Ensuring continuous and accurate monitoring of energy consumption.
- Predictive Maintenance: Identifying potential equipment failures before they occur.
- Energy Optimization: Reducing energy waste without compromising production quality.
Solution Proposed
- Anomaly Detection using Autoencoders to identify unusual energy consumption patterns.
- Implementing Gradient Boosting algorithms to predict equipment failures and LSTM (Long Short-Term Memory) networks for accurate energy demand forecasting.
- Implementing Energy Management Systems to control and optimize energy usage across the manufacturing process and representing in an interactive dashboard for real-time energy monitoring, alerting, and reporting.
- Deploying IoT sensors and edge computing devices for real-time data collection and processing.
Outcome
- Achieved a 15% reduction in energy consumption within the first six months.
- Improved Overall Equipment Effectiveness (OEE) significantly.
- Reduced unplanned downtime considerably through predictive maintenance.
- Notable reduction in carbon emissions, contributing to sustainability goals.
Design & Thinking Wins
- Scalability: The solution can be scaled across multiple manufacturing plants.
- Customization: Tailored algorithms and dashboards to meet specific client needs.
- User-Friendly Interface: Easy-to-use dashboards and reporting tools for non-technical users.
- Integration Capability: Seamless integration with existing manufacturing and IT infrastructure.
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Disclaimer: The outline showcases the typical challenges, solutions, designs, and outcomes for industries and functions, in general, based on Affine’s prowess in the Industry. The outcomes would be much higher for specific clients as they would be based on their data and specific problems to be solved.
