Energy Management Systems - Balance Production & Energy Consumption

At the start of all manufacturing processes, there is energy. In fact, all products you see on store shelves or internet shops wouldn’t exist without energy and the conversion of that energy through the manufacturing process, from raw materials all the way to finished products. Energy doesn’t come without a cost, both financially and via environmental impact. For most manufacturers, two main goals drive operations – energy efficiency and high production.  

These two goals may seem to be working against each other, but energy efficiency in U.S. manufacturing has made incredible strides in recent years, meaning less energy is required to produce the same amount. Still, it’s important for manufacturers to find that balance between high production and low consumption charges. Doing so can seem difficult, but managing energy consumption responsibly doesn’t necessarily mean sacrificing productivity. In fact, there are now tools to aid manufacturers in balancing the two. An Energy Management System (EMS) makes it possible to keep both efficiency and productivity top priorities. Benefits of employing an EMS stretch across multiple areas of the manufacturing process.

Accessible Energy Data and Analysis

With the EMS module of CIMAG, supervisors and managers can easily access real-time data and analytics when it comes to energy and water consumption and CO2 emissions. Overall consumption is also broken down visually for each machine on the shop floor, giving even more precise information to drive decision-making. The module incorporates various colors to quickly identify problem areas where either production consistently misses KPIs or where usage exceeds expectations.

The first step in data-driven decision-making involves collecting data. The EMS module consistently provides managers with that critical data and analysis of it. What decisions does this data drive? Because the data is broken down by machine and by time frame, managers can avoid running machines during periods of high peak rates. The module also notes areas of wasted consumption, so decision-makers can look for opportunities to improve efficiency and lower the amount of wasted energy.   

Additionally, data provided by the EMS module allows owners to track their CO2 footprint. Reducing their carbon footprint where possible is a goal for most manufacturers. This goal may stem from personal conviction or the desire to qualify for energy incentives for doing so. The types of available incentives vary by industry and sometimes, by state. However, for all government energy programs, accurate and up-to-date data is critical for achieving and maintaining compliance and eligibility for these. 

CIMAG helps track those emissions and provides the accurate data needed to qualify for those incentives – making it easier for manufacturers to obtain them and retain them each year.

Increase Energy Efficiency and Overall Productivity

By having easy access to energy data as it relates to each part of the production process, businesses can address the issue of efficiency. As mentioned above, analyzing per-machine energy usage during different times allows for greater scheduling efficiency to avoid those peak rate times. As the module integrates with the rest of the CIMAG software, those decisions regarding scheduling are made in real-time, limiting the amount of time wasted operating inefficiently. 

Overall, this allows manufacturers to produce more, spending less on energy in doing so – thus decreasing their product energy cost. This term refers to the amount of energy it takes during an item’s production. That amount negatively correlates with productivity measures. So, decreased product energy cost means increased productivity. That is a win-win for organizations in any industry.

Determining Best Energy Source Combination for Operations

One area of analysis unique to our software is its ability to analyze data that does not currently exist. The unique “what if” analysis capabilities of the CIMAG MES software allow businesses to think hypothetically about energy sources and make decisions based on those findings. The software analyzes different aspects of production and how they are currently powered. Also, it shows changes an organization may see from switching to an alternative energy source. Most often, electricity and gas energy are two of the most readily available energy options. However, the module also helps to identify opportunities to switch to other energy forms (wind, solar, etc).   

If it’s discovered that making an energy switch saves money during a particular aspect of production, manufacturers can then compare cost savings to the investment needed for the switch to determine the next steps. Having this information available means business owners can make critical decisions driven by data.

Customized Energy Management System from IMCO Software

The EMS module is a great addition to the CIMAG MES software, as it provides continuous data collection and analysis to help owners make the best decisions for production. Between the “what-if” capabilities and its real-time energy usage information, it’s the perfect tool to help manufacturers balance energy consumption and production and make the best decisions for both sustainability and growth.  

An investment in an EMS means more responsible production processes and better sustainability for organizations and for the environment. In order to fully grasp its unique capabilities, we encourage any manufacturer to see the module 

If you are interested in learning more about our EMS module or the CIMAG MES software solution as a whole – we would love to provide a free demo. These demos allow us to articulate how the software can help your company reach its production and efficiency goals.  Contact us today to schedule a consultation.