MESC – Achieving Energy Efficiency with Real-Time Manufacturing Analytics

Introduction

MESC, a manufacturing leader, faced challenges in optimizing energy usage while maintaining high production standards. With increasing operational costs, MESC sought a solution that could provide real-time insights into energy consumption, enabling better decision-making and greater efficiency.

Covansys was selected to implement an Industrial 4.0 platform to integrate production data with energy consumption metrics for a comprehensive energy management solution.

Challenges in Achieving Energy Efficiency

Key Issues Impacting Energy Consumption and Production

MESC encountered several obstacles in its pursuit of energy efficiency and performance improvement

Inefficient Energy Usage

High operational costs due to uncontrolled energy consumption across production lines.

Lack of Real-Time Monitoring

Inability to track energy consumption metrics in real-time, leading to inefficient resource allocation.

High Operational Costs

Energy consumption was not optimized for production output, resulting in high costs.

Data Silos

Disconnected production and energy data, making it difficult to draw meaningful conclusions for decision-making.

Manual Processes

Dependence on manual energy audits and performance reports, leading to delays and inaccuracies in addressing inefficiencies.

Streamlining Operations with Covansys’ Approach (Solution)

To address these challenges, Covansys implemented an Industrial 4.0 platform that integrated production data with real-time energy consumption metrics.

The solution was designed to provide comprehensive visibility and insights into energy use across all stages of manufacturing

Energy-Linked Manufacturing Platform

Integrated production and energy data for real-time monitoring.

Real-Time Analytics

Enabled immediate access to energy consumption patterns and trends.

Detailed Efficiency Analysis

Provided actionable insights for optimizing energy usage across production lines.

Cost Reduction Measures

Identified areas where energy could be saved, significantly lowering operational costs

Performance Enhancement

Allowed for better resource allocation, improving overall manufacturing performance.

Scalable Infrastructure

Designed to grow with MESC’s production needs, ensuring long-term energy efficiency improvements.

Reliable Energy Efficiency for MESC

Covansys delivered a seamless integration of production and energy data that enabled MESC to optimize its energy usage while boosting overall operational efficiency.
With real-time energy metrics, the company now has the visibility needed to make informed decisions and ensure sustainable manufacturing processes.

Reduction in Energy Consumption

Decrease in Operational Costs

Improvement in Manufacturing Performance

Increase in Efficiency

Conclusion

By integrating real-time energy metrics into MESC’s manufacturing platform, Covansys helped optimize energy usage and reduce costs. The system allowed MESC to enhance overall manufacturing performance and make data-driven decisions for long-term efficiency improvements.