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HYDRAEnergy Management

Detect energy wasteand reduce production costs!

MOTIVATION

Cost pressure and energy politics

Not only have the prices for natural gas and elec­tricity been rising steadily for years but so have the resulting cost pressures on industrial companies. Additionally, there is a growing corporate aware­ness of their natural environment since the image of a company is, at least in part, influenced by its environmental and climate protection activities.

Current developments in environmental policy require that industry makes changes in dealing with key environmental issues. Many countries have already implemented legal regulations that oblige companies to reduce energy consumption through appropriate measures. Companies are thereby forced to actively save energy and im­plement an energy management system, e. g., complying with DIN EN ISO 50001.

Practical functions in the HYDRA module Energy Management (EMG) provide effective support for companies in collecting, monitoring and systema­tically reducing energy consumption. In addition, HYDRA EMG is on the list of eligible software of the Federal Office of Economics and Export Control in Germany (www.bafa.de).

APPLICATIONSchematic energy management

By connecting energy counters to a Manufacturing Execution System (MES), the control loops defined in DIN EN ISO 50001 can be implemented at a reasonable cost. For this purpose, HYDRA EMG establishes the necessary connection to the data from the production processes and comprises the following functions:

• Automatic and manual collection of energy consumption• Varied and individually designed evaluation of energy data• Analysis of consumption relating to machines, order and articles• Consumption statement covering any period of times• Process orientated performance collection and analysis• Calculating and monitoring of KPIs including escalation management• Consumption profiles to detect peaks• Energy optimized production control

Formulate company-specific target definitions for an energy

efficiency program.Introduction of a planning process to pursue goals.

Implement the planning of the energy management system by building management structures,

training, communication and documentation.

Evaluation of numbers, data and facts to help develop

improvement measures for processes and procedures.

Review of process compliance through internal analysis and

audits, derivation of correction and preventive measures.

Act Plan

ISO50001Check D

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Master data and configuration

In order to know where one can begin reducing their required energy usage, which includes electrical energy, heat, water, and compressed air or gas, the consumption of that energy must first be recorded manually or via counters. HYDRA EMG can provide the necessary counter management, which allows for both automatic and manual data collection, with the help of collection plans and correction functions.

• Create and maintain master data for energy counters• Illustrate hierarchical counter structures including „virtual” counters• Simplified configuration for energy counter layout• Define any accounting periods• Flexible reading plans based on activity calendars• Collection dialogs are user­friendly and can be used on mobile devices

FLEXIBILITY

TRANSPARENCYCurrent information, evaluations and analysis

In order to make accurate decisions relating to energy usage, a targeted analysis of energy consumption is required. For this purpose, HYDRA EMG offers many flexible evaluations and diagrams, in addition to the physical counter locations in a graphical layout.

• Monitoring energy to show consumption and reference values• Correlative performance analysis, e.g., comparing orders, articles and

machine statuses• Graphical energy counter layout including display of KPIs• Flexible consumption analysis with Pivot functions• Visualization of energy data on the office client and on the shop floor terminal• Display of actual values including evaluations based on historical data• Display of expected energy consumption in the graphical planning

INTEGRATION

Benefits of an integrated energy management

In contrast to classical energy management systems, valuable synergy effects and benefits can be achieved using HYDRA EMG in conjunction with other MES applications:

• Using existing MES infrastructure with mobile and stationary collection devices• Uniform collection dialogs for energy values and other production data• Correlation of energy data including machine statuses, orders, produced articles

and other production data• General KPI calculation, e. g., specific energy consumption• Joint escalation management with other MES applications• Monitoring expected energy consumption during the detailed planning of orders

which includes energy quotas• Using energy data for preventive and condition­based maintenance

Needs­based, tailor­made MES applications

Every MES solution is as individual as the compa­ny using it. An MES must be of a modular design and largely configurable in order to turn field­test­ed standard functions into tailor­made solutions.

Extensive requirements covering all business sectors and levels must be considered: From user­friendly collection and information functions for operators to reliable statistics for the management.

The examples for HYDRA EMG applications illus­trat ed in this brochure are a combination of standard MES products by MPDV. These pro­ducts, characterizing a state­of­the­art MES, can be selected needs­based and integrated without interfaces:

• Shop Floor Integration Services: Interfaces to machines and production lines plus data col­lection and information functions for operators

• MES Applications: Powerful programs to pro­cess data and functions for data mainte­nance, detailed planning, monitoring and controlling

• Smart MES Applications: For usage on mobile devices and in web browsers

• MES­Cockpit Applications: Dashboards for general KPIs

• Enterprise Integration Services: Basic functions and interfaces to seamlessly integrate the MES into an existing IT landscape

© 2017 MPDV Mikrolab GmbH | Doku Ident: PREMG_EN 08/2017.The mentioned product names are trademarks of the respective producers or suppliers. HYDRA® is a registered trademark of MPDV Mikrolab GmbH.

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