Energy Management System For Machine Factory

This system is used in a factory in Japan. It monitors the energy consumption of the production line for car engines and "visualizes" the energy usage compared to the production output. By doing so, it supports efficient operation of the facility and analysis of efficient ways of using energy.

This system was introduced in order to measure the energy usage of a production line in a factory. They chose DIASYS Netmation because they liked its ability to meet their requests. They wanted the system to determine whether the preset target for the energy consumption rate is satisfied and to display an alarm when the actual energy consumption rate exceeds the planned value.

This system can measure the energy consumption for each facility. Energy can be saved by changing the operation of the facilities where energy is consumed wastefully. In addition, energy usage can be checked both from the factory and remotely from the energy management section at the headquarters to allow quick response to abnormal usage.

• Centralized monitoring
  DIASYS Netmation can centrally monitor the production equipment at the site controlled by two or more Programmable Logic Controllers (PLCs) from third parties.
  Based on the signals each PLC receives, DIASYS Netmation can manage factory operation as a whole including setup of an energy saving plan and feedback of management information.
• Alarm display
  An alarm is displayed as a warning on a large monitor installed at the site when the actual energy consumption rate exceeds the planned value. Additionally, the past records, recent comparison, and the alarm occurrence and the recovery history for each piece of equipment and the history can be displayed.

• Trend display
  The production status of a product, the operation status of equipment, and failure signals are managed by using trend information. Two types of trends can be displayed: a real time trend for a maximum of 24 hours and a historical trend for a maximum of 30 days.

• Energy management
  DIASYS Netmation can manage energy consumption rates on a graphic screen or a trend screen by using control logic to process the signals received from third party PLCs. DIASYS Netmation can determine in real time whether the preset target for the energy consumption rate is satisfied.
  The energy usage and the pass/fail results are displayed on large monitors installed at several locations in the factory to allow the people concerned throughout the factory to get the data. Also, the system is connected to the customer's company network to enable remote monitoring from anywhere in the company.
• Managing operation status of facilities
  DIASYS Netmation collects operation data from production facilities, visualizes the difference in the operation pattern of each facility depending on seasons and time slots, and improves the operation.
• Reports
  The data collected from the production equipment at the site is managed as daily, monthly, and yearly reports. The reported data can be modified and edited easily in Excel and can be used as an operator's report.

• Energy Visualization
  Rich monitoring and analysis functions facilitate efficient operation and energy saving. Those functions include consumption rate calculation, energy usage display, conversion to CO2, and comparison of operation status of facilities based on Gantt chart.
• Remote Monitoring Function
  The remote monitoring function using a intranet enables monitoring of production status from a PC in another building inside the factory with the same quality level as monitoring at the site.