"The SiteWatch Energy Management System is a Plant Manager's dream. It allows me more transparency into how operators, machines and our process is performing." — Plant Manager, Battery Industry
How can machine monitoring improve efficiency? When a customer understands machine, or production line, or system energy use, that knowledge can be used to build a complete view of manufacturing or operating costs. Without understanding how machines or lines consume energy, only a partial picture can ever be realized.
How will additional information effect operations? Data itself does not have an impact, yet it can be used to inform a customer on how and why energy is consumed on a more specific level than a whole-building meter data can provide. Operators will not understand the energy impact of their actions without direct measurement of the machines they are operating.
Benchmarking, tracking energy improvements, and helping operators function more efficiently are all direct applications for SiteWatch!
Operations Management – Vastly Improved Visibility.
With new wireless IOT technology, facility owners, operations teams, and engineers can gain more detailed visibility into energy consumption, machine efficiency, and machine health at the equipment level – e.g. pumps, compressors, chillers, condensers, heaters, and virtually any other energy consuming device – at a fraction of the cost of traditional SCADA or building management systems.
Whether the application is a commercial building, a manufacturing facility, a hospital, or a college campus, detailed energy data will enable savings and improve operations. Gain a comprehensive view of your mechanical and electrical system operations in real-time. This has created a new approach to operations management, focused less on ‘fire-fighting’ and more on proactive management.
Inexpensive, clip-on sensors (and clamp-on meters) to measure energy-use and other parameters – natural gas, air, water, temperature, pressure, humidity, CO2, vibration etc. - allow managers to identify operational inefficiencies, reduce waste, and calculate operating costs accurately. These sensors can be installed within hours – not days or weeks – and data flows immediately.
What Should You Monitor?
The scope of monitoring varies based on objectives, machinery and systems in place, and other site-specific requirements. Generally, an installation covers:
- The largest machines - and energy-consuming equipment - the most expensive to run.
- Critical systems - on which other processes depend - e.g. compressed air, cooling water.
- Troublesome machines - requiring excessive maintenance and repair.
- Older equipment - more temperamental or less energy efficient.
- Equipment located remotely - half-a-mile away or across the country.
The ROI from Monitoring
Investing in IOT solutions is a growing priority for manufacturers. New technology such as remote energy- and machine-monitoring should not simply be considered an expense, but rather an investment in a cost-reduction toolset that can improve how your company operates and make it more competitive.
- Identify wasted energy - due to unnecessary run-time, incorrect settings or operator error.
- Reduce operating costs - by optimizing processes, machine settings, and schedules.
- Overlay data - both energy and non-energy - to calculate operating costs accurately.
- Minimize downtime - through early warning of machine-failure from common causes.
- Identify peak demand - i.e. when peaks are set and which equipment is responsible.
- Save labor - by automating data capture and creating one-click Management Reports.