Case Study
Project objective
The project consists of the analysis of energy management by solving 3 problems: measurement and collection of consumption, compact historical storage that allows its later analysis and generation of reports that join consumption and production information.
Information is collected by means of network analyzers or by taking advantage of existing information from inverters or electronic starters. In other cases, the information on equipment operating hours is sufficient to be able to apply energy efficiency and saving policies.
In batch production systems, the energy study must relate consumption to the batches produced of the different types of products.
It is important to involve in the improvement process all the internal and external personnel linked to the production process, seeking a mentalization of the whole team in the search for efficiency.
- Control hardware: Rockwell Automation.
- SCADA: iFix from General Electric.
- Historian: Rockwell Historian.
- Analysis: Rockwell's VantagePoint and custom web applications developed in Microsoft .NET environment and CrystalReport reports.
- Database: ORACLE 11g.
- Networks: Ethernet.
- Continuous analysis makes it possible to verify efficiency by analyzing the energy/production ratio, and also to detect instantaneous deviations by comparing the current consumption of the batch produced with the historical consumption trend of previous batches of the same product.
- In this way, system failures due to drops in system efficiency can be detected and, in the medium term, improvement measures can be taken to increase efficiency.
- After the analysis of historical data, it will be possible to improve the system by taking into account external factors such as the energy market situation, diversification of energy sources, technological changes, etc...
- The improvement has repercussions in the reduction of waste, reduction of quality losses and optimization of human and material production resources.