Energy management has become the top agenda for Enterprises globally – imperative not just for increasing profitability but also for planning and tracking sustainability initiatives. One of the most critical components, Energy – including power, fuel, etc.- contributes to around 30-70% of operating costs for enterprises. Today we talk about one such enterprise and its inspiring journey towards IoT-powered Energy Analytics.

Energy contributes to about 30-70% of operating costs for enterprises.

An illustrious century of operations worldwide, but..

A global manufacturing company grossing more than 5 Billion USD annually, the group has 15 diverse business divisions offering consumer, office, and industrial products and services. With an illustrious 123 years of operations and a long history of pioneering manufacturing excellence, they manufacture everything from bespoke engineering solutions for satellites to branded consumer products. 

Back in early 2014, they realized that their profits might start stagnating soon. Always on the lookout for increasing efficiency and optimizing their processes, the company zoned in on a very critical factor that was driving up their costs- Energy

This was not new. Energy management had been a pain point for this manufacturing giant for years. Manual readings taken in long intervals, often with human errors and inconsistencies, would lead to a lack of transparency in the system. Leaks would frequently go undetected. Energy-saving initiatives would fail for want of proper tracking and monitoring capabilities. Even in places where consumption data was available, it was in dead log books that made decision-making painstakingly slow. It was high time now to put an end to this.

Looking for solutions.

The team started scouting for alternative solutions to their energy-management problems. But this was no easy feat either. The legacy manufacturer had various kinds of meters peppered throughout their plants. Different locations had different communication backbones in place. And they wanted to do more than just bringing data from sensors to the screen. They knew the immense power that data had, and that is what they intended to harness.

They knew the immense power that data had, and that is exactly what they intended to harness.

Enter SmartSense. With its strong analytics engine and advanced customizable dashboards, it promised everything that they were looking for. Capable of predicting possible faults in advance, the platform could send user-defined alerts to the person-in-charge aiding prompt resolution. Via automated daily reports configured role-wise and location-wise, each person could get concise overviews every day. Moreover, it supported hundreds of types of meters and sensors and was compatible with over 12 industry communication protocols.

IoT powered Energy Analytics

In 2014, they took their first step towards creating a truly connected smart factory- installing SmartSense in one of their plants in western India. 

Harnessing the power of data.

Within a few months, this IoT-powered solution started showing results. Through constant monitoring and analysis by SmartSense, they would get instant alerts on events of any predicted anomalies, feeder breaches, or unusual consumption. They could now see all their flow (water/air/fuel) as well as PLC data on a single dashboard– customized to their needs. Huge energy savings from continuous monitoring resulted in higher profits and a smaller carbon footprint. The GIS dashboard gave senior management a bird’s-eye view of all plants. Integrating production data via SAP, they could now monitor Specific Energy Consumption across various production lines.

GIS dashboard

Power quality and consumption insights

Instead of second-guessing themselves, the decision-makers could now make data-driven decisions, set targets, and track them.

For issues that they previously did not even know existed, they could now get automated alerts and resolution recommendations sent directly to the operators in-charge. 

Automatic Anomaly Detection

Going one step forward.

Via their use of SmartSense EMS, they started reaping the low-hanging fruits almost immediately. Going forward, they replicated this success at other locations as well. Today, they have employed SmartSense in 7 different locations, covering 1000 nodes and over 400 critical assets including motors, compressors, and transformers. Using SmartSense for energy as well as predictive asset management, they have successfully reduced unplanned downtime by 40%, manpower requirement by 15%,  and energy consumption by 10%.

What started as an initiative to bring consumption data to a centralized dashboard, morphed into a process of getting to know their manufacturing plants like never before. 

Gone are the days of dumb spreadsheets, they now have data that speaks to them!

Global manufacturing and facility management enterprises like Godrej, SKF, Intas, PepsiCo, and JLL are employing SmartSense to analyze and optimize their energy consumption, and significantly lowering their bottom lines.

Ready to write your own success story?

Contact us to schedule a free value-discovery workshop for your enterprise today!

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