Digital Transformation in Food and Beverage, CPG Energy ... · Overall Equiment and Energy...

The Schneider Electric industrial software business and AVEVA have merged to trade as AVEVA Group plc, a UK listed company.

The Schneider Electric and Life Is On trademarks are owned by Schneider Electric and are being licensed to AVEVA by Schneider Electric.

Digital Transformation in Food and Beverage, CPG

Energy Management & Sustainability

Confidential Property of AVEVA Group plc.

Presented by: Xavier Marfa, F&B Business Development EURA

Across the production cycle, the assets cycles and the product cycle

Energy Management & Sustainability

• Improves electrical network reliability

• Improves ROI on electrical assets

• Enables ability to verify utility bill

• Sustainable sourcing (asset)

• Reduce WAGES (water, air, gas, electricity & steam)

usage (production)

• Agility for packaging materials and formulation

(products)

• Link energy data and operational data together, to

enable energy data with operational context.

Business Value:

Reduce spend on WAGES, simplify &

standarise energy management processes,

llower carbon footprint and sustain savings

over time

• Energy Performance for Manufacturing

Simplify & standardize your

energy management processes

Reduce how much you spend

on energy to run your facility

Provide visibility on energy usage

in your facility & reduce waste

Manage your demand levels

to lower your electricity bill

Check your utility bill is

100% correct & ensure your

utility does not overcharge you

Monitor the quality of power

feeding important assets

to prevent equipment

damage or malfunction

Identify when equipment is

no longer running efficiency

and may need maintenance

Reduce production downtime

Diagnose and correct

electrical problems

causing process downtime

and production losses

Avoid circuit overloads and

nuisance breaker trips

Increase operational efficiency

Identify & resolve problems quickly

with advanced electrical

diagnostic information

Adjust operations and

modify processes with

less risk for better efficiency

and increased output

Value Propositions

Lower your carbon footprint

& sustain savings over time

Track real-time energy usage

against baselines and

established targets

Develop standard energy

reporting & corrective actions

Enable ISO 50001 certification

Improve equipment performance

Achieve CO2 reduction goals

with advanced energy

management tools

Maintain a high level

of energy efficiency

with continuous monitoring

Overall Equiment and Energy Efficiency (OEE+E)

3 Steps of Energy SavingLow Hanging Fruits – High Energy Consumption Equipment – Production Process

Upgrade to energy-saving devices – LED lighting, variable

speed or variable frequency drives


• High energy consumption equipment – air compressor, boiler, chiller, cooling tower, heater, motors etc.

• Time-based or Condition-based maintenance to ensure these equipment run smoothly

• Upgrade to energy saving model, install energy saving module to boost the energy efficiency of these

equipment


• Link up the energy consumption data with production activities – contextualize energy data

• Analyze and uncover the opportunity of improvement in energy consumed by production

• Through Continuous Improvement, drive the most energy-efficient way of operation

Customer Pain Points

Lack of data and meaningful information for improvement

Meter for whole

plant

Meter at

MSB1

Meter at

MSB2Meter at

MSB3

2 processing

lines 4 packaging lines

Water chiller, air

compressor, lighting etc.

• No meter beyond Main Switch

Board to give enough electricity /

power details for the line or

equipment beyond that.

• The data and information is too

generic and not detailed enough

for analysis and decision making.

• Same situation could be happened

for water, air, gas, and steam – do

not have detailed level of

measurement after site main inlet /

generation point.

Confidential Property of Schneider Electric |


Manual data recording

• Manual data recording.

• No data management system for data storage,

trending, analysis

• Resource wasted on non-value activities, e.g.

data recording, walk around, data sorting &

categorization, analysis.

• Things get worse when amount of data to be

handled is big – months, years.

• Questionable consistency and accuracy of

data.



Lack of visibility on real-time energy information

• Unable to monitor the energy system in real time

• Unable to foresee potential issue impacting

equipment performance , e.g. transformer

deterioration, unbalance current load etc.

• Any breakdown in electrical network or equipment

can affect production and operations.


Customer Pain PointsUnable to correlate the electricity usage to the bill

• Just pay the bill as per charged, with no

means to verify the billing.

• Especially for power factor penalty, unable to

justify the number or even take action to

reduce it in the future, due to inability to

track the bad power factor.


Customer Pain PointsUnable to correlate the energy consumption to the operation

• Unable to correlate the energy

consumption to the operation.

• Cannot justify the energy consumption,

and also cannot foresee the trend of

energy consumption.

• Unable to perform good analysis and

come out with improvement plan.

Energy Consumption vs Production Volume

Production Volume

Energy Consumption


Energy Management Journey

Maintain efficiency.

Ensure operations, facility teams & energy managers can work together for continuous improvement andoperational excellence.

Make improvements.

Optimize process energy use and reduce unplanned downtime for improved performance and output.

Process Energy Efficiency

& System Reliability

Awareness

Improvement

Sustainability

Optimization &

Continuous Improvement

Become energy aware.

Monitor the power coming into the facility as well as how much energy is used by the key processes using energy aware infrastructures. Identify & eliminate energy waste.

Energy Tracking

& Waste Reduction

Site Energy

is the total energy consumed by your plant

and the level at which utilities charge you for energy

Process Energy

is the energy used by machines and

equipment for producing your product

Energy PerformanceProvides comprehensive industrial energy management applications at all levels


Energy PerformanceEnergy Performance provides a comprehensive energy management solution.

Energy Data

Level of details

(depends on the

presence of meters)

Manufacturing

Operational Data

Energy data with

operational context

Consumption of:

Electricity

Water

Gas

Air

Steam

Site

Line

Process

Equipment

Production State

Shift / Crew

Process Order

Product

Recipe

Energy consumption

per unit or PO

Energy intensity of

product

Energy intensity of

production state

Energy intensity of

shift or crew

Energy Performance – Energy data with Operational Context

PME

MES / Historian / System Platform / Excel

Energy PerformanceConfidential Property of Schneider Electric |

Energy Monitoring & Management


• Collect, calculate and report costs for

departments, processes, shifts, lines,

or equipment

• Track non-electrical utilities, Water,

Gas, etc. (WAGES)

• Reduce peak Demand and Power

Factor penalties

• Track electrical parameters

• Monitor power quality correction

equipment

• Continuous Power Quality Monitoring

• Ensuring Electrical Network Health

Collect, Measure and Trend Energy Data

Identify process energy efficiency and operate with energy cost

as a real business driver

• Track energy intensity KPIs

• Monitor energy usage trend

in the context of process events

• Energy metric per Production State

• Energy metric per Shift

• Energy metric per Work Order

• Energy metric per Product

• Energy metric per certain production states &

product & shift

• Etc.

• Analyze energy usage vs operation 4Ms

• Man (shift / crew), method (behavior)

• Machine (line / equipment), material (product)

Energy questions answered

Example of Energy Data Question Answered

Hourly water consumption in Process A for past

2 shifts.

Energy consumption of specific period

Monthly electricity consumption in Equipment B

– YTD 2017 vs same period of 2016,

comparison side by side.

Comparison of energy consumption for same

period of different years

Yearly energy consumption trend in Site C for

past 5 years.

Total energy consumption, considering all

Water, Air, Gas, Electricity, and Steam

Site D power consumption diagram. Power distribution details – balance or not

Power demand trend across the plant Location of peak demand identified, able to

work on power factor penalty reduction.

Plant status of voltage, current, power factor,

harmonics, short duration event

Power quality information of the plant

Energy questions answered, enriched with production context

Example of Energy Data Question Answered

Energy consumption per unit / PO Unit energy consumption / Energy Intensity

Apple to apple energy consumption comparison by

normalizing based on production volume.

Energy consumption of certain product in

Line A

Energy consumption of material

Allocate energy consumption per product, to treat the

energy consumption as one of the material costs, to price

the product correctly.

Energy consumption during cold start vs

Energy consumption during warm start

Energy consumption of production event

Should I shutdown the oven during or keep it warm at lower

temperature during 3 days maintenance? Identify the best

practice dealing with specific production event.

Energy consumption of certain crew during

running

Energy consumption of man and method

Human behavior effect to energy consumption. Identify the

best team to be benchmarked.

Questions?


Digital Transformation in Food and Beverage, CPG Energy ... · Overall Equiment and Energy...

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