Manufacturing agent

Energy and utilization analysis

Find where energy and machine time are wasted and point to where to recover them.

What it does

At the close of each metering interval, the agent sets meter readings against machine run-time and booked output to show energy and machine hours used per unit produced, by machine and by shift. It lists the periods where energy and running time went in without output coming out, and a person decides what to change.

Without it: Energy and utilization data sits unused, so waste continues unnoticed across the floor.

Idle-but-powered time is split from running time and from genuine downtime
Each machine is set against its own history and its peers on the same product
Intervals with a failed meter read are named and excluded, not interpolated
Compressed air, lighting and HVAC load is held apart from machine load

Illustrative example

The 06:00 interval closes with 1,840 kWh drawn against 3.1 tonnes booked. Two ring frames sat at near-running power for 90 minutes with no output booked against them, and a third comes out at 0.61 kWh per kg where a peer on the same count runs 0.48. The energy engineer takes both into the maintenance meeting and picks which one to investigate.

Reads

Energy meters

kWh per interval

Run-time records

Running, idle, down

Output records

Booked output per machine

Runs

Energy and utilization analysis

Watch

Starts when

A metering interval closes and consumption data lands