DATA COLLECTION MANAGEMENT


create harmonic currents which actually results in higher energy costs. Where VSDs are not


suitable, there are often other ways to reduce energy consumption.


STARTING POINT The tools for a successful manufacturing energy strategy can be found in the ever-growing mountain of data, readily found in most manufacturing enterprises. Putting this to good use can make fast advancements in the realms of equipment efficiency, workforce efficiency and the all- important energy efficiency, without the dreaded rip-and-replace of high-cost assets. Most modern industrial assets have IoT capabilities and can already record data about energy consumption. And, for the assets that don’t, IoT devices can be fitted very simply and at low cost. Energy consumption data is an enabler of efficiency quick-wins, when assets that are still performing their tasks properly are less efficient than when the asset was new. Putting this data to use often identifies areas of industrial environments that would otherwise have been overlooked, opening new operational improvement decisions that can now be made with greater confidence.


Manufacturing energy strategies need to be all encompassing, looking to reduce energy intensity without compromising on productivity


or multiple, an in-depth understanding of asset health is imperative to finding efficiency quick wins that may not be identifiable by sight alone. The right software choice will let


maintenance professionals can assess the issue remotely and often put a plan into action immediately. Accelerating how quickly an issue can be solved and if in-person intervention is still


“Most modern industrial assets have IoT capabilities and can already record data about energy consumption. And, for the assets that don’t, IoT devices can be fitted very simply and at low cost. Energy consumption data is an enabler of efficiency quick-wins”


So, a successful and cost-effective energy strategy should always start with data. Manufacturers should seek a combined IT and OT collaborative system that can act as a complete command and control solution for contextualised energy use. This requires taking some big steps towards digital transformation, and is seldom a simple process, but the dividends are huge across three key areas:


1. Equipment efficiency Whether a manufacturer is managing one facility


Timely maintenance programmes informed by data help reduce both energy consumption and unplanned downtime


manufacturer’s drill down to specific asset’s information, such as temperature, pressure and of course energy consumption. This granular detail can identify the causes of


efficiency issues such as worn bearings or weakened pulleys. Such inefficiencies may not put an immediate stop to production but over time they increase the energy consumption of a facility. Timely maintenance programmes informed by data help reduce both energy consumption and unplanned downtime.


2. Workforce efficiency Expert maintenance is often needed to keep operations moving, requiring in-person intervention. Getting the right expertise to a facility, or an asset within a facility, to investigate a fault often means lost production. This whole process can be streamlined through the company- wide access to a single digital thread. Expert


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required, the operator has all the information they need to begin fixing as soon as they arrive on site.


3. Energy efficiency The right software provides the intelligence to make better decisions and the confidence to shift power-heavy processes to avoid peak energy times. Where assets or processes that demand the highest amount of power can operate when the cost of energy is at its lowest, costs are reduced significantly. Not only does this save money, it helps the grid balance energy demands towards renewable sources. Rising energy costs impact everyone and we all


need to take action to save our wallets and better protect the environment. This mission is infinitely more complicated for manufacturers who are working with stakeholders and managing razor- thin budgets, but improving efficiency isn’t an all or nothing approach. New equipment isn’t always the most financially sound option. The right software will enable UK manufacturers to reduce their energy usage, improve efficiency and optimise the workforce without disruption. AVEVA Operations Control has the power to optimise and revolutionise your UK manufacturing enterprise.


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ENERGY & SUSTAINABILITY SOLUTIONS - Autumn 2023 17


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