Domestic Plant - Energy Management System for Engine Production Equipment
The system provides support for analyzing the efficient operation of equipment and effective methods for using energy by monitoring energy usage on a vehicle engine production line at a domestic plant and visualizing the energy usage in relation to production results.
Background to Introduction and Challenges Faced
The system was introduced to ascertain energy usage for a plant production line.
The system from Mitsubishi Power was adopted after being recognized for its ability to meet the customer requirements, including determining whether pre-designated specific energy consumption target values had been attained, and displaying alarms when actual specific energy consumption values had exceeded planned values.
Effects of Introduction
The system made it possible to monitor energy usage on a per-equipment basis, and by making changes to the operation of equipment using energy in a wasteful manner, promoted energy savings.
Moreover, as the state of energy usage could be monitored in real-time at the plant and by the energy management division at the remote head office, the customer gained the ability to quickly respond to abnormalities.
Monitoring and Operational Features
Multiple on-site manufacturing units controlled with programmable logic controllers (PLC) produced by other companies are monitored at once. Based on the signals read from each PLC, plant operation can be centrally controlled, including the configuration of energy saving plans and reflection in management information.
When specific energy consumption has exceeded the planned value, an alarm is shown in real-time on a large display monitor installed on-site to draw attention. In addition, a per-device history of alarm triggering and restoration can be displayed in terms of past results and on a per-shift basis.
Equipment operational status and fault signals can be managed through a trend display.
Real-time trends covering periods of up to 24 hours and historical trends for up to 30 days can be displayed.
Management Support Features
By applying logical computations to the signals collected from PLCs produced by other companies, specific energy consumption can be managed through graphics and trend displays. Attainment of pre-designated specific energy consumption target values can be determined in real-time.
Energy usage and the results of energy usage determinations are shown on large monitors installed in various locations throughout the plant, allowing plant personnel to quickly ascertain the current state of energy usage. In addition, the system connects to the customer' s internal network to allow remote monitoring to be freely implemented from anywhere inside the company.
Equipment Operational Status Management
Operating data on production equipment is also collected in detail, clearly illustrating the differences in equipment operating patterns depending on factors such as the season or time of day, leading to operational improvements.
Data collected from on-site manufacturing equipment is managed in the form of daily, monthly and yearly reports.
Form data can be easily corrected or edited in Excel and used for purposes such as the preparation of operator reports.
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