IN16 - Energy Intelligence—Making Manufacturing More Productive

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PUBLIC INFORMATION

Energy IntelligenceMaking Manufacturing More Productive


World-wide energy consumption will increase over

70% 2035by

Why Energy Management?

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Optimizes resources and reduces waste.

WATER AIR GAS ELECTRICITY STEAM

3

Energy Management Strategy


MONITORCONSUMPTION

CONTROLUSAGE

ANALYZEDATA

4


MONITORCONSUMPTION

for Business Performance Insight

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Analyze energy usage trends comparedto historical patterns & forecasts

Trigger alerts from abnormal energy usage

Gain accurate visibility of asset energy consumption


Connect People to Information

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MACHINES & TESTERS

INDUSTRIAL “THINGS”

MATERIAL & TRANSPORT

SHOP FLOOR PERSONNEL

PRINTERS & LABEL SERVICES

PLCS & SCANNERS

FINANCIALS HR LOGISTICS QUALITY WAREHOUSEERP

Motor 1

Status = Running

kWh = 5442

Cost Per kWh = $0.14

Current SKU = 0013857

Quality Check = PASSED

Motor 2

Status = Idle

kWh = 0


Current SKU = NONE

Quality Check = NONE

Co

sts

Dashboards with Context

Example Results:

• Energy Costs per Motor

• Energy Cost per Product Recipe

• Cost per Good Quality Part / Unit

• ….

MONITORCONSUMPTION


Physical ModelConnect data sources

Logical ModelOrganize for Presentation

Desktop

Mobile

Connected and organized Data becomes InformationMONITORCONSUMPTION


Motor 1

Status = Running

kWh = 5442


Current SKU = 0013857

Quality Check = PASSED

Motor 2

Status = Idle

kWh = 0


Current SKU = NONE

Quality Check = NONE

• All this data comes from different places (PLCs, Drives, ERP, Electric

Co.)

• It’s organized in a Unified Production Model which makes sense to

people

• The data for different motors can come from different sources

• The structure is still the same for all motors (or whatever object)

• It can be easily applied to new motors – dashboards and reports still

work!

Motor 3

Status: Vision Sys

kWh: Power Monitor

Cost Per kWh: Utility Web Site

Current SKU: SQL Table

Quality Check:

Manual Entry

Motor 1

Status:

AB PLC

kWh: Power Monitor



Quality Check:

Manual Entry

Motor 2

Status: Siemen PLC

kWh: Meter



Quality Check:

Manual Entry

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PLCS & SCANNERS


The Value of the Logical Model (Unified Production Model)MONITORCONSUMPTION


Before Enterprise Manufacturing Intelligence, this was a Huge Effort!

1. Generate a spreadsheet in Excel

2. Paste in the historical data from the HMI trend

3. Go to the electric company’s website for rates; type it into Excel

4. Get IT to query the ERP database for schedule info; import to Excel

5. Use sneaker-net to gather the quality data and type it into Excel

6. Align the data by time stamp and calculate the desired results

7. Do it again for each motor!

Motor 3

Status: Vision Sys

kWh: Power Monitor



Quality Check:

Manual Entry

Motor 1

Status:

AB PLC

kWh: Power Monitor



Quality Check:

Manual Entry

Motor 2

Status: Siemen PLC

kWh: Meter



Quality Check:

Manual Entry

Result =

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PLCS & SCANNERS


Accomplishing the Same Thing Using Traditional TechniquesMONITORCONSUMPTION


• Once the model is built, reports and dashboards are easy to create without

knowledge of the underlying data sources and systems.

• The model looks like the real world – not a bunch of code.

• The model is easily extended; reports and dashboards are reusable.

• The data is always up-to date, and is not replicated (important for

validation).

• It saves huge amounts of time and errors vs. manual report generation.

• Visualizations are role-specific, device agnostic, and secured by login.

Information

Software

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PLCS & SCANNERS


Information Approach is Far SuperiorMONITORCONSUMPTION


ANALYZEDATA

for Energy Intelligence

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Reduce energy per unit produced

Extend production capacity utilizing same levels of energy usage

Correlate real-time energy & production data for actionable view of business performance


Recipe StoredCan Reuse

5 Daysof Raw Materials On-Hand

Machine Uptime: 92%

Batch ID: 4531980

80 psiDrying Range Good

Oven Temp350˚ F

Smart Plant OperationsCorrelate Energy with Production Data

1100 kWh Energy Used Today

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Energy Intelligence Software

Web-based reporting,

trending and dashboard capabilities

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The classical approach

External consultancy or experts implementing

energy monitoring

Disconnected from other existing systems and data

Existing information can/will not be used

Local production is not involved in the whole

approach

The Energy Intelligence approach

Energy monitoring as an integrated approach

- existing systems, data and information will be used

Experts support implementation and use of system

Local production is involved in the whole approach

System can be extended or combined with other

performance management initiatives


Cold

Storage

Onward

processin

g

or

packagingSeparationIntake Chilling Fat Control

Pasteurization

PasteurizationHomogenisation

Cream Aging Tanks

Finished Milk

Tanks

Cold

Storage

Onward

processing

or

packaging

Curd

Separator Evaporator

Pasteurization

Cheese Formers

Whey

SeparatorCheese Vats Pasterization Sprey

DrierCristalization

Sweet

Whey

Salt Whey

Onward

processing

or packaging

BoilersCIP Refregeration

Cold

RefrigerantElectricity Water Fuel

Hot

WaterSteam

Milk brought

to site via

tanker

CUSUM plot for deviation

trending (Chillers)

Energy Dashboards

and Analysis

Dryer optimization

Steam reporting

ANALYZEDATA

Trigger and Analyze

on mobile clients


CONTROLUSAGE

for Efficient Resource Utilization

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Leverage existing automation systems to manage energy usage

Production requirements can be met at the lowest possible resource costs

Reduce demand charges & manage real-time power purchases


Energy Consumption Data

Production & Business-Level Data

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Demand Management

Generator Controls

Power Quality Monitoring

Emergency Load Shedding

Gain Advanced Control & Minimize Cost

Distribution System Monitoring

Power Factor Control

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Demand Response Solutions


Drive continuous business value

Focus on factors you can control

Leverage integrated control & information technology

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Energy Management

Success Stories


Reduces annual utility costs by more than 10%.

Decreases energy consumption by 15 %.

Achieves energy savings paybackin just over 1 year.

US

A

US

A

US

A

UK

Saves $150,000+ annually on energy costs.

UK

Reduces annual water consumptionby 100 million+ gallons.

US

A

Saves over €15,000 per

month on energy costs.

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SOLUTION BENEFITSCHALLENGE

Realizing the Immediate Impacts of Implementing a Corporate Energy Program

• Rising Energy Costs

• Disparate and Manual Systems

• Payback of 2 Years

• 10% Annual Savings

• Payback in 12 Months

“Rockwell Automation energy management

solution is flexible, scalable, customizable and

integrates with SAP and other systems.”

Danny Hamilton, Director Energy Engineering, Tyson Foods

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“Rockwell Automation took

a team-centered approach,

sharing expertise and

helping us take ownership.”

®

REDUCED ENERGY

CONSUMPTION 15%

REDUCED OVERALL

CARBON FOOTPRINT 25%24


€15,300 monthly saving in electricity consumption

Easy-to-understand reports

Multiple data sourcesfor analysis

Easily expandable to multiple sites

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DEMO


Leveraging The Connected EnterpriseEnergy Management Solutions

ENERGY-AWARE CONTROL SYSTEM• Smart Connected Assets report energy usage

• Real-time data in context of production

• Actionable reports/dashboards

• “Smart Factory” as node on “Smart Grid”

IN16 - Energy Intelligence—Making Manufacturing More Productive

Technology

Transcript of IN16 - Energy Intelligence—Making Manufacturing More Productive