Energy Efficiency What can Smart Manufacturing do for you?
Profilo Relatore • Inizio percorso lavorativo 1984 come Tecnico Automazione presso azienda produttrice sedili per auto ( Gruppo Fiat ) • 1992 ingresso in Schneider Electric come Tecnico pre-post vendita, lavoro al Tunnell della Manica • 1999 : Marketing Responsabile di prodotto SCADA – MES e Telemetria, prescrizione nostri prodotti • 2007 : Marketing Promotore soluzioni SCADA – MES , collegamento diretto con R&D per sviluppo prodotti • 2010 : Solution Architect Expert Process Automation e Energy Efficiency
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How can I optimize energy consumption and minimize emissions while maximizing production at the lowest cost?
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EU requirements are leading the way
5 December, 2015
By this date all non-SME enterprises must have a an energy audit or have a certified Energy Management system in place. Mandatory for big plants, and energy intensive sectors
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Why does it matter for Industry? Because Industry uses more energy than any other segment!
• A 25% savings would save 7% of the world’s electricity • An average facility can reduce consumption by 10 to 20%
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Smart Manufacturing needs to address critical issues within the Industry Value Chain I need help capturing knowledge for my transitioning workforce
How can
innovation drive profits?
How do I improve
workforce productivity?
I need to improve
product quality How can I
I need to achieve
real-time visibility
reduce the energy costs? How can I
How do I achieve
sustainability? How can I introduce new products faster?
reduce downtime? How can I better manage my
global supply chain?
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How can technology help us?
Two Worlds That Coming Together
Sustainability planning
Information Technology
Web Services
Energy management
Asset management Business Operations
Operative Technology
Energy availability
Process Control Safety / Security
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Manufacturing Energy optimisation Track energy & process data to improve: OEE+EE Energy per unit produced
Dashboards
CO2 performance Energy by area MES
Services
Energy Monitoring System
Supervisory Control System
Integrated hardware infrastructure SEPAM
ION 7650
EGX300 Gateway
PM 6200
PLC
VSD 9
Overall Equipment Effectiveness (OEE) The plant was down for 2 of 16 scheduled hours, produced 1120 of 1400 targeted widgets of which 1064 were good quality
OEE = Availability * Performance * Quality 14/16
87.5%
1120/1400
* 80%
1064/1120
* 95%
= 66.5%
T. Calendar Time Planned Maintenance
A. Scheduled Time B. Running Time
Downtime
C. Target Output Slow Running
D. Actual Output E. Good Output
Poor Quality 10
OEE+EE > Why the +EE (Energy Efficiency) ? • What about energy? • Different products consume different amounts of energy • Are you running them at the optimal time of day? • OEE+EE = Availability * Performance * Quality * Energy Efficiency
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Some examples of Optimization through automation Reduce energy waste at the source of overconsumption. Use energy data to predict preventative maintenance. Engage in Demand Response programs.
Energy Monitoring System
Supervisory Control System
Integrated hardware infrastructure SEPAM
ION 7650
EGX300 Gateway
PM 6200
PLC
VSD 12
Process demand management
Reduce energy waste at the source of overconsumption
• Eliminate energy waste when production not running • Improve the energy efficiency of a plant in standby & sleep modes (manufacturing pauses, night, week-ends and holidays) • In most cases baseline consumption is 50% to 70% of nominal consumption Manufacturing factory typical power curve
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Example: Sleep / Idle Mode
SCENARIO: • Process / production is halted upstream.
ACTION: • • • •
Automation libraries detect production/process halt. Start-up costs are evaluated against running costs. Buffer is exceeded, automation libraries trigger sleep cycle. Drives and machines enter “Idle” state, slowing down and shutting down where possible.
BENEFITS: • Net savings of energy & OPEX.
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Use energy data to predict preventative maintenance Asset Operation Solution (AOS) puts maintenance to a next level,
Failure Anticipation Ageing Capabilities
Obsolescence Management Product Life-Cycle Management & Retrofit
using digitization
Proactive Maintenance
Dealing with asset information in
Sustainable Reliability Big Data
order to optimize asset Lifecycle and reduce downtime costs due to
Predictive Maintenance Condition Based Maintenance
failure
Service Requests
Preventive Maintenance
Asset Operation is a combination of hardware, connectivity and software
Time Based Maintenance Reactive Maintenance Corrective Maintenance
Alarming
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Example: Predictive Maintenance SCENARIO: ● Air compressor is beginning to require maintenance.
INDICATION: ● No reduction in air pressure has been detected. ● Energy consumption consistently exceeds baseline & target.
ACTION: ● Compressor undergoes maintenance.
BENEFITS: ● Net savings on energy and OPEX. 16
Example: Proactive Maintenance or Improvement
kWh per kg grouped by biscuit type
Biscuit type
SCENARIO: • Biscuit production line
ACTION: • Interventions to improve the performance (OEE+E) of a system or a part of it
BENEFITS: • Increased production, reduce energy consumption 17
Engage in Demand Response programs. The production lines must be able to adapt to new production requirements
SCENARIO: ● Production of plastic bottles
ACTION: ● Supervisor indicates the type of bottle to produce the necessary air ● Automation respond by analysing process sequence, choosing how many compressors are needed and reducing other low-priority processes to slow-running.
BENEFITS: ● Optimization of energy consumption ● Reduce operating costs.
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Simplified access to data, everywhere, everytime
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Still some resistance to change… • OEM not easy to convince to change standard: • Difficulty convincing the OEM to change on its machines and accepted by the End User • Arguments : energy savings in medium term for the EU
• Cost of the solution : • The Green machine / Green production lines require additional costs • Arguments : analysis of the initial situation with verification step by step of the new contest, and ROI simulation
• Effects psychological • Fear of having a loss of performance of the machine • Not all End User are sensitive to Energy Efficiency • Energy Efficiency not only electric power, but also optimisation of the raw materials, recycling, waste reduction, etc. • Arguments : real examples through the MEASURE
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CONCLUSION: Go beyond manufacturing and optimize ALL major domains of your enterprise domains of competence
One unique OPEN architecture of supervision Operations Management
Energy Management
Efficiency of operating costs and monitoring of potential energy savings at the corporate level.
Process management and machinery Central Supervision Single resource to increase productivity and respond quickly
Management IT environments
Building Management
Security Management For companies efficiency is a mandatory way
Methods and integrated systems
Right information to the right users at the right time
Up to
Saving Capex and Opex Costs
When energy monitoring is combined with automation and control infrastructures, energy efficiency can grow by as much as 30%.�
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Grazie
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