MPDV: Reduce your production cost using HYDRA's energy management by MPDV

Energy management with HYDRA EMG

Application & benefits
Detect energy waste and reduce production costs!
For years, rising prices for natural gas and electricity have put enormous cost pressure on many industrial companies. Additionally, a growing environmental awareness can be observed: Today, the image of a company is also influenced by its environmental and climate protection activities.
Also, current developments in environmental policy require that industry makes changes in complying with key environmental issues. Many countries have already implemented legal regulations that oblige companies to reduce energy consumption through appropriate measures. Companies are thereby forced to actively save energy and implement an energy management system, e.g. complying with DIN EN ISO 50001. As a result, companies can profit from benefits in energy procurement.
Proven functions in the HYDRA module Energy Management (EMG) effectively support the detailed recording, demand-oriented monitoring and systematic reduction of your energy consumption. HYDRA EMG also offers functions for efficient production planning, consumption analysis and billing as well as energy management.
Benefits to energy management with HYDRA EMG
Reduced overhead by detailed assignment of energy consumption
Cost savings through optimal utilization and targeted shutdown of machines
More transparency for the identification of energyintensive machines and processes
Utilization of possible cost advantages in energy procurement (e. g. energy quotas)
Compliance with requirements of relevant standards (e. g. DIN EN ISO 50001)
Many business units across the enterprise can benefit from an MES system such as HYDRA. Our ROI Analyzer reveals the untapped potentials that are still hidden within your production processes and will show you how they can be assessed monetarily.
Highlights
Identify energy guzzlers and save costs
By connecting energy counters to a Manufacturing Execution System (MES), the control loops defined in DIN EN ISO 50001 can be implemented at a reasonable cost. However, increasing transparency with regard to energy consumption is also a frequently cited reason for introducing such a module. HYDRA EMG correlates the necessary data from the production process and includes the following essential functions:
Automatic and manual collection of energy consumption
Varied and individually designed evaluation of energy data
Analysis of consumption relating to machines, orders and articles
Consumption statements covering any period of time
Process orientated output collection and analysis
Calculating and monitoring of KPIs including escalation management
Consumption profiles to detect peaks
Energy optimized production control
Additionally, HYDRA EMG can be tightly integrated with other HYDRA applications. Examples include:
Shop floor scheduling
Shop floor data collection
Machine data collection
Tool and resource management
As with all HYDRA applications, we offer targeted training courses in order to make the implementation of the system as efficient as possible. In the training courses you will learn how to integrate your requirements into the system conveniently.
Functions
Making energy consumption transparent
In order to find ways of reducing energy consumption, the consumption must first be recorded via counters. In addition to measuring devices for electrical energy, counters are also required to measure heat quantities, water, compressed air or gas. HYDRA EMG provides counter management which allows both automatic and manual data collection using collection plans and correction functions.

Collection of energy consumption
Regardless of whether the consumption values are entered manually or automatically, a reliable database is absolutely necessary to calculate the energy costs and/or to initiate optimization measures.
Example functions

A record of all energy types (e. g. electricity, gas, water, steam, compressed air)
Manual input of current meter readings or delta consumption, also via mobile devices
Timed reminders for manual reading via activity calendar
Plausibility check of manually collected values
Automatic transfer of counter readings and output values from any collection device
Visualization in real time
In many cases, the display of energy consumption or current power consumption is crucial. For example, an operator can tell whether the machine is running within specifications or whether a leak in the supply of compressed air or steam has occurred.
Example functions

Visualization of current energy data at the office PC and/or at the shop floor terminal
Graphical energy counter layout including display of KPIs
Posting of limit violations
Evaluation, analysis and invoicing
The targeted analysis of energy consumption is an important factor for making the right decisions in production. For this purpose, HYDRA EMG offers many customizable evaluations and diagrams in a graphical layout, in addition to the physical counter locations.
Example functions

Monitoring energy to show consumption and reference values
Correlative output analysis, e. g. comparing orders, articles and machine statuses
Display of actual values including evaluations based on historical data
Calculation of KPIs according to VDMA standard sheet 66412
Flexible consumption analysis with Pivot functions
Consumption statements over userdefinable periods
Energy-optimized production planning
Energy plays an essential role in production planning. HYDRA EMG supports the energy-optimized planning of orders and operations.
Example functions

Display of expected energy consumption in the graphic planning application
Visualization and inclusion of energy budgets
Calculation and display of possible peaks
Support of control loops according to DIN EN ISO 50001
HYDRA EMG supplies data and evaluations for the PDCA control loop (Plan - Do - Check - Act) according to DIN EN ISO 50001 and supports the certification of the company.
Example functions

Collection of consumption and output
Posting and longterm storage
Visualization and analysis options
Logistical assignment of consumption
Definition and tracing of measures
Production planning according to energy demand
Assistance with billing and post production calculation
Display of Specific Requirements
Because every manufacturing company has unique requirements, HYDRA EMG offers a large array of versatile configuration options while the advantages of standard software can still be maintained.
Further details

HYDRA EMG can be configured via extensive master data and flexible settings without the need for custom programming:
Create and maintain master data for energy counters
Illustrating hierarchical counter structures including "virtual" counters
Assignment of energy consumption to departments (also proportionally)
Simple configuration for energy counter layout
Definition of any accounting periods
Reading plans based on activity calendars
Modern development tools are available to the user for a detailed individualization in the form of customer-specific functions, evaluations and displays in HYDRA EMG.
Energy management in the environment of many other MES applications
In contrast to classical energy management systems, valuable synergy effects and benefits can be achieved using HYDRA EMG in conjunction with other HYDRA applications:
Further details

Integration into shop floor scheduling
Display of expected energy consumption during the detailed planning phase of orders
Consideration of defined energy quotas in detailed planning
Integration into shop floor data collection
Correlation of energy data with machine statuses, orders, produced articles and other production data
General KPI calculation, e. g., specific energy consumption
Integration into tool and resource management and machine data collection
Display of energy consumption in a graphic machine layout displayed on large monitors in the shop floor
Correlation of energy data including machine statuses and conditions
Comprehensive calculation of KPIs such as consumption per machine hour
Use of energy data for preventive and conditionbased maintenance
Resourcerelated functions for counters, e. g., status, maintenance
Integration into other HYDRA applications
Using existing MES infrastructure with mobile and stationary collection devices
Uniform collection dialogs for energy values and other production data
Joint escalation management with other MES applications

Application & benefits

Detect energy waste and reduce production costs!

For years, rising prices for natural gas and electricity have put enormous cost pressure on many industrial companies. Additionally, a growing environmental awareness can be observed: Today, the image of a company is also influenced by its environmental and climate protection activities.

Also, current developments in environmental policy require that industry makes changes in complying with key environmental issues. Many countries have already implemented legal regulations that oblige companies to reduce energy consumption through appropriate measures. Companies are thereby forced to actively save energy and implement an energy management system, e.g. complying with DIN EN ISO 50001. As a result, companies can profit from benefits in energy procurement.

Proven functions in the HYDRA module Energy Management (EMG) effectively support the detailed recording, demand-oriented monitoring and systematic reduction of your energy consumption. HYDRA EMG also offers functions for efficient production planning, consumption analysis and billing as well as energy management.

Benefits to energy management with HYDRA EMG

Reduced overhead by detailed assignment of energy consumption
Cost savings through optimal utilization and targeted shutdown of machines
More transparency for the identification of energyintensive machines and processes
Utilization of possible cost advantages in energy procurement (e. g. energy quotas)
Compliance with requirements of relevant standards (e. g. DIN EN ISO 50001)

Many business units across the enterprise can benefit from an MES system such as HYDRA. Our ROI Analyzer reveals the untapped potentials that are still hidden within your production processes and will show you how they can be assessed monetarily.

Highlights

Identify energy guzzlers and save costs

By connecting energy counters to a Manufacturing Execution System (MES), the control loops defined in DIN EN ISO 50001 can be implemented at a reasonable cost. However, increasing transparency with regard to energy consumption is also a frequently cited reason for introducing such a module. HYDRA EMG correlates the necessary data from the production process and includes the following essential functions:

Automatic and manual collection of energy consumption
Varied and individually designed evaluation of energy data
Analysis of consumption relating to machines, orders and articles
Consumption statements covering any period of time
Process orientated output collection and analysis
Calculating and monitoring of KPIs including escalation management
Consumption profiles to detect peaks
Energy optimized production control

Additionally, HYDRA EMG can be tightly integrated with other HYDRA applications. Examples include:

As with all HYDRA applications, we offer targeted training courses in order to make the implementation of the system as efficient as possible. In the training courses you will learn how to integrate your requirements into the system conveniently.

Functions

Making energy consumption transparent

In order to find ways of reducing energy consumption, the consumption must first be recorded via counters. In addition to measuring devices for electrical energy, counters are also required to measure heat quantities, water, compressed air or gas. HYDRA EMG provides counter management which allows both automatic and manual data collection using collection plans and correction functions.

Collection of energy consumption

Regardless of whether the consumption values are entered manually or automatically, a reliable database is absolutely necessary to calculate the energy costs and/or to initiate optimization measures.

Example functions
A record of all energy types (e. g. electricity, gas, water, steam, compressed air)
Manual input of current meter readings or delta consumption, also via mobile devices
Timed reminders for manual reading via activity calendar
Plausibility check of manually collected values
Automatic transfer of counter readings and output values from any collection device

Visualization in real time

In many cases, the display of energy consumption or current power consumption is crucial. For example, an operator can tell whether the machine is running within specifications or whether a leak in the supply of compressed air or steam has occurred.

Example functions
Visualization of current energy data at the office PC and/or at the shop floor terminal
Graphical energy counter layout including display of KPIs
Posting of limit violations

Evaluation, analysis and invoicing

The targeted analysis of energy consumption is an important factor for making the right decisions in production. For this purpose, HYDRA EMG offers many customizable evaluations and diagrams in a graphical layout, in addition to the physical counter locations.

Example functions
Monitoring energy to show consumption and reference values
Correlative output analysis, e. g. comparing orders, articles and machine statuses
Display of actual values including evaluations based on historical data
Calculation of KPIs according to VDMA standard sheet 66412
Flexible consumption analysis with Pivot functions
Consumption statements over userdefinable periods

Energy-optimized production planning

Energy plays an essential role in production planning. HYDRA EMG supports the energy-optimized planning of orders and operations.

Example functions
Display of expected energy consumption in the graphic planning application
Visualization and inclusion of energy budgets
Calculation and display of possible peaks

Support of control loops according to DIN EN ISO 50001

HYDRA EMG supplies data and evaluations for the PDCA control loop (Plan - Do - Check - Act) according to DIN EN ISO 50001 and supports the certification of the company.

Example functions
Collection of consumption and output
Posting and longterm storage
Visualization and analysis options
Logistical assignment of consumption
Definition and tracing of measures
Production planning according to energy demand
Assistance with billing and post production calculation

Display of Specific Requirements

Because every manufacturing company has unique requirements, HYDRA EMG offers a large array of versatile configuration options while the advantages of standard software can still be maintained.

Further details
HYDRA EMG can be configured via extensive master data and flexible settings without the need for custom programming:
Create and maintain master data for energy counters
Illustrating hierarchical counter structures including "virtual" counters
Assignment of energy consumption to departments (also proportionally)
Simple configuration for energy counter layout
Definition of any accounting periods
Reading plans based on activity calendars
Modern development tools are available to the user for a detailed individualization in the form of customer-specific functions, evaluations and displays in HYDRA EMG.

Energy management in the environment of many other MES applications

In contrast to classical energy management systems, valuable synergy effects and benefits can be achieved using HYDRA EMG in conjunction with other HYDRA applications:

Further details
Integration into shop floor scheduling
Display of expected energy consumption during the detailed planning phase of orders
Consideration of defined energy quotas in detailed planning
Integration into shop floor data collection
Correlation of energy data with machine statuses, orders, produced articles and other production data
General KPI calculation, e. g., specific energy consumption
Integration into tool and resource management and machine data collection
Display of energy consumption in a graphic machine layout displayed on large monitors in the shop floor
Correlation of energy data including machine statuses and conditions
Comprehensive calculation of KPIs such as consumption per machine hour
Use of energy data for preventive and conditionbased maintenance
Resourcerelated functions for counters, e. g., status, maintenance
Integration into other HYDRA applications
Using existing MES infrastructure with mobile and stationary collection devices
Uniform collection dialogs for energy values and other production data
Joint escalation management with other MES applications

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Brochure Energy Management with HYDRA EMG

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