Introduction
In cable manufacturing, energy consumption is a major operational cost and directly impacts production efficiency. Without visibility into how energy usage correlates with output, manufacturers often face high energy intensity and reduced operational performance. To address this, the cable manufacturer partnered with Covansys Technologies to implement an energy versus production analytics solution. By linking energy consumption data directly to production output, Covansys enabled the facility to optimize energy per unit of production, reduce wastage, and increase overall operational efficiency.
Challenges in Energy Management
Key Issues Affecting Production Performance
Lamprell faced several challenges in ensuring consistent connectivity across their industrial yard
Optimizing Energy and Production with Covansys’ Solution
Covansys deployed a real-time energy monitoring and analytics system tailored to the cable manufacturing process.
Connected factory energy meters to track consumption continuously.
Linked energy consumption directly with production output metrics.
Centralized platform to monitor energy intensity per production unit.
Identified unusual energy consumption patterns for corrective actions.
Provided actionable recommendations to reduce energy use while maintaining production levels.
Designed to integrate additional machines or production lines in the future.
Enhanced Production Efficiency and Energy Control
Covansys’ solution provided the manufacturer with a clear view of energy use relative to production output. The system enabled data-driven operational decisions, reduced energy intensity, and improved production efficiency without compromising output quality.
Reduction in energy consumption per production unit
Increase in overall production efficiency
Operational cost savings through optimized energy use
Identification of abnormal energy usage patterns
Conclusion
By implementing an integrated energy vs production analytics solution, Covansys empowered the cable manufacturer to reduce energy intensity, enhance production efficiency, and make informed, real-time operational decisions. The solution provided actionable insights, improved resource management, and supported sustainable, cost-effective manufacturing.
Driving Smarter Manufacturing Operations
Covansys delivers intelligent energy monitoring and analytics solutions that connect consumption data to production metrics. See how real-time insights can boost efficiency, reduce waste, and optimize operations.