See how Total Utilities helped a leading NZ retail chain achieve easy savings through intelligent energy insights from our Panoramic Power real-time energy management solution.
With 94 sensors installed across several sites on critical systems, they were able to cut costs, reduce carbon emissions, and progress toward sustainability goals.
Discover how real-time energy monitoring can lead to big savings and help your business meet sustainability goals. Check out the full case study now!
Improve manufacturing operations and cut costs by setting operational efficiency KPIs.
In the last 3 months the global economy has been turned on it’s head due to the Covid-19 pandemic. In light of this, manufacturers are faced with the pressures of producing more high-quality goods, with less money, time and resources. Regulations are becoming more stringent and competition is growing in a smaller market.
To achieve the goals of lean operation, industrial manufacturers need to constantly monitor, benchmark and improve.
KPIs can prove a valuable gauge of progress, helping manufacturers to set and achieve their business goals and maintain critical business resiliency.
1. Optimise maintenance schedules
Many manufacturers still operate preventative maintenance schedules. Preventative maintenance is costly because only 15% to 20% of all components fail after a predictable time. Reducing operational costs means approaching maintenance in a new way.
A predictive maintenance program – servicing machines based on need-based early stage notifications – is much more efficient than a Fixed Time Maintenance (FTM) Preventative Program.
This allows manufacturers to be proactive, rather than reactive when it comes to equipment repairs and operational downtime. They can make informed decisions, based on transparency and a pattern that is most suitable to their business.
Reduced costs and eliminated outages should be demonstrable when manufacturers transition to a predictive maintenance mode and track overall downtime.
2. Improve true downtime cost (TDC) and downtime percentage
Consider the true cost of unplanned downtime. Do you know what the cost of downtime is to your business? Decreasing downtime and improving operational efficiencies can save manufacturers millions of dollars.
By calculating your True Downtime Cost and showing measured improvements in this realm, you can illustrate saved time and money, as well as reduced waste and create a data-driven, quantifiable resiliency plan.
Understanding true costs can also help you to make cost justification within day-to-day management decisions.
3. Improve Rolled Throughput Yield (RTY)
RTY is the probability that a single unit can pass through a series of process steps free of defects. Acceptable Rolled Throughput Yield is dependent upon a very high individual first time yield for each process. It is the sum of the parts measurement that is most critical to overall operational efficiency.
RTY is a great operational efficiency KPI to track as it alerts manufacturers to the health of their entire operation, rolling all processes into a single measurement.
4. Maximizing capacity utilisation
Diminish the cost of owning and maintaining equipment by using equipment to its full capacity.
By measuring the output that is actually produced and comparing it to its potential maximum output, manufacturers can understand the efficiency of their operation. Increasing capacity utilisation increases overall efficiency.
An OEE score presents “an accurate picture of how effectively your manufacturing process is running. And, it makes it easy to track improvements in that process over time.”
Conclusion
These Operational Efficiency KPIs will give you an indication of the overall efficiency of your operation and a real sense of your resiliency needs.
Any downward trends in performance will require deeper analysis. Manufacturers should also look at processes, systems, and the performance of equipment.
With improved visibility and intelligent use of smart technologies throughout the plant, manufacturers can take a leap forward when boosting operational efficiency throughout the business. Using real-time data allows you to plan, in a quantifiable way, the need for a backup plan.
Talk to us to learn more about how energy insights can drive your energy and resilience strategy.
If you don’t know precisely how, when and where energy is being used across your business, how can you understand where your energy costs really lie, or the best opportunities to improve energy and operational performance?
Working together with Centrica Business Solutions, Total Utilities is the exclusive partner delivering the Energy Insight product solution to the New Zealand market. Using Centrica’s wireless sensor technology, you can monitor energy usage in real-time – right down to device and equipment level. When this information is relayed to our PowerRadarTM analysis platform, you can access the intelligence you need to develop a data-driven energy strategy.
The Power of IoT
Our Internet of Things (IoT) technology is providing the deep energy insights that uncover flexibility and value in your operations and generation assets. This is a ‘game changer’ in raising energy performance across all types of organisations – from manufacturing and leisure – to healthcare and education.
Energy Insight technology provides full visibility of energy usage across your site, or multiple sites – right down to individual device level. We attach self-powered, wireless sensors to equipment and processes, such as conveyor belts, lighting circuits, chillers, or any other energy consuming assets.
This instantly transmits real-time data to our cloud-based PowerRadar analytics and reporting platform. You can then access this intelligence to inform your decision making and improve efficiencies.
Deep energy insights
Hundreds of sensors, which can measure both heat and power consumption, can be installed within a few hours and won’t cause disruption to operations. Data provided by our IoT technology enables organisations to quickly identify and resolve energy waste. It can also pinpoint opportunities to reduce high peak-time energy costs by moderating consumption in these periods.
The biggest gains of IoT energy insights are often seen in improved operational efficiency and business resilience. By ensuring that critical equipment is operating optimally and preventing costly disruption, or even breakdown, large operational cost savings can be achieved. Continuity of operations is also assured, which is particularly beneficial in manufacturing environments.
The results of IoT energy optimisation
We’re seeing the positive results of our IoT enabled energy optimisation across all business sectors, including Progressive Enterprises New Zealand.
Join us on Monday as we discuss how the Internet of Things is changing Energy Management and how insights can support sustainable business. Register here.
Create a sustainable energy strategy, and build a competitive advantage with powerful energy insights that provide complete visibility of your energy footprint.
Now more than ever businesses globally are looking for wastage and holding utility costs to account by requiring detailed operational reports.
As the owner of your energy strategy, it is imperative that you have end-to-end visibility of your energy footprint. Obtaining this level of visibility will provide you with energy intelligence around consumption and performance of on-site assets. These energy insights will give your business the ability to:
Understand how energy is being used across your entire footprint
Identify processes and specific devices where energy is being wasted
Manage risks and opportunities in real-time to ensure performance of assets
Manage all your data in a single energy management system
Having a centralised view of your entire energy footprint and device-level data eliminates the time and complexity involved with managing energy data in multiple platforms. A single platform that integrates with other systems creates a holistic view of your energy infrastructure that can be used to inform a single, full report.
In addition, using a single platform to manage your energy data means you always know that you’re looking at real-time, accurate intelligence. This can help you make data-driven decisions about your energy strategy that are based on the most up-to-date energy data displayed in the energy management platform.
The granular level of intelligence provided by device-level data will provide you with a deeper understanding of your energy use and help to accurately form your energy strategy. This information can be used to identify ways to future-proof your strategy to:
Improve operational efficiency
Uncover growth opportunities
Unlock new revenue streams
Identify new energy technologies
Use Energy Insights data to improve operational efficiency
Data can help your business analyse capital equipment to identify inefficiencies and determine when equipment should be replaced or requires maintenance. By keeping equipment working efficiently and performing at its optimum level, you can avoid costly downtime and reduce business risk.
Use data to uncover growth opportunities
Better energy insights can free up resources to support growth initiatives, turning energy from a commodity cost to a value-adding resource. Growth opportunities can also be achieved when your strategy successfully lowers the costs associated with energy.
Use data to unlock new revenue streams
The information gathered through end-to-end visibility can help your business leverage its energy use, flexibility and existing assets. This opportunity unlocks new revenue streams for your business by allowing you to curtail energy use or sell surplus energy back to the grid through Demand Response (DR), demand management and asset optimisation.
Use data to identify new energy technologies
End-to-end visibility of your energy footprint can help to inform decisions on using new technologies such as solar and battery storage, back-up power generation, or cogeneration (also known as Combined Heat and Power or CHP) to help drive energy optimisation and improve resilience.
The visibility of your energy footprint will grow as you adopt new technologies, but by using a centralised system to holistically monitor and manage your data, this should not add any extra complexity. In fact, your energy management system can provide you with the data you need to justify your investments in on-site energy generation.
Why businesses need to choose the right platform and provider
It is imperative that businesses partner with a provider that has the right energy insight tools and a platform that collects and centralises granular, device-level data.
Working with Total Utilities, businesses can be sure that they’ll benefit from experience and expertise. We are the New Zealand providers of Centrica’s Energy Insight solution and integrated energy management platform, PowerRadar®. These tools are generating new opportunities across all types of industry, giving organisations the ability to manage real-time, device-level energy intelligence in a single, holistic view.
Contact our experts to find out how we can help you obtain real-time visibility of your energy performance and develop a strategy that turns your energy into a competitive asset.
