Ampla Express. Enabling energy management in the production environment

Transcription

1 Ampla Express Enabling energy management in the production environment

2 Ampla Express Pressure to more effectively manage energy is mounting at a rapid rate. > Energy costs are increasing in real and historic terms > Supply chain sustainability is at the top of the agenda, driving the need to reduce waste and emissions > Rapidly developing environmentally-centric government policy is driving strict energy regulation Sustainability managers are expected to find increasingly innovative ways of being efficient with energy consumption. Optimizing energy consumption requires a steady stream of reliable information: Production and energy consumption figures need to be captured, impacts quantified and root causes identified. Ampla Express, built on Schneider Electric s leading operation management software equips you with the information you need to achieve your energy KPIs. The software is designed to assist in the optimization of energy usage and production processes. Two applications of Ampla Express are available - Ampla Express: Insights and Ampla Express: OEE+E (Overall Equipment Effectiveness + Energy). The Insights option is designed to provide users with a complete, meaningful representation of energy usage in the production environment. The OEE+E option combines OEE, a well understood metric that can assist in the optimization of production processes, with an energy component to maximize the effectiveness of your assets. Ampla Express: Insights Accelerate energy-based decisions The development and execution of energy-centric initiatives are frequently stalled by barriers in the decision-making process. Timely decision making requires access to on-demand, up-to-date and intelligent data. Ampla Express: Insights empowers managers to make such timely decisions by: > Collating energy related data in context with production and presenting it as easy-to-understand, near real-time intelligence for analysis, data mining, querying and reporting > Presenting energy data in a way that is visual where correlations, causations and trends can be easily identified > Allowing data to be customized to display the right level of detail Manage energy consumption It is clear that pressure exists to continuously reduce energy consumption, per unit production. Managers need to be able to identify possible opportunities to increase efficiency. Ampla Express: Insights can present opportunities to increase efficiency by: > Providing insights into actual energy consumed, whether water, air, gas, electricity, or steam > Gathering near real-time production energy usage data that is relevant, with appropriate detail > Presenting opportunities to reduce, reuse and recycle energy > Presenting energy consumption costs in a production context. For example, associating usage with equipment allocation, crew, shifts, and material grades Identify opportunities to reduce energy wastage The reduction of energy waste in production is a key component of any plan that aims to maximize energy efficiency. It involves minimizing any unnecessary resource and energy usage within plant processes. Ampla Express: Insights can help you achieve this by: > Providing comprehensive, detailed and meaningful data that identifies potential wastage, actual wastage and its root causes > Displaying potential opportunities to reduce, reuse and recycle energy > Enabling managers to conduct analysis at an adaptable level of detail. Even low energy wastage points can be revealed which, when viewed as a whole, can potentially add up to significant energy wastage Continuous improvement in efficient energy consumption Management is under increasing pressure to continuously optimize energy consumption. To achieve this, it is necessary to assess the gaps that exist between actual and ideal performance. Ampla Express: Insights facilitates this by: > Visually displaying real-time Key Performance Indicators (KPIs) on an easy-to-read dashboard > Enabling managers to measure and evolve KPIs > Displaying trends so that the progress of improvement initiatives can be assessed

3 Ampla Express: Insights, built on Schneider Electric s leading operation management software, provides a complete, meaningful representation of energy usage in the production environment. Ampla Express: Insights centralizes energy usage data into meaningful dashboards Total kwh costs are attached to production processes Gantt chart used to display downtime periods by location

4 Ampla Express: Insights Features Improve process efficiencies The continuous improvement of process efficiencies within a plant is a key component of effective energy management. Ampla Express: Insights provides an accurate overall picture of a plant s inputs and outputs, including materials, consumables, energy, waste, emissions, reject and product output without the time, errors and costs often associated with manual data entry. This information can then be used by management to help them make better, timely and more informed decisions for improved process efficiencies. Calculate Key Performance Indicators (KPIs) Actual production process performance can be mapped in order to set KPIs and viewed on a graphical dashboard display. The dashboard shows instant measurements such as performance, total CO 2 -e, CO 2 -e per output unit, total cost per kwh, kwh cost per output unit etc. Additionally, Ampla Express: Insights can show the trend of these measures over time so that management can gauge the impact of improvement initiatives or operational changes. Features at a glance > Combines power and energy data > Near real-time power monitoring capabilities > Tracks energy costs using utility model rates > Automatic near real-time logging for an accurate production picture > Single point of entry for manually entered production values to reduce errors > Graphical dashboard display to visually present KPIs, trends etc. > Compliant with industry standards, (ISA-95, OPC, B2MML) Benefits at a glance > Provides reliable, and accurate energy data in the context of the operating environment > Displays energy information on entire plant process, not just a single area > Automatically gathers and presents information in meaningful dashboards, reports and applications clients > Presents opportunities for reducing energy costs > A scalable solution that can be used for one area of the plant, the whole plant or multiple plants > Easily integrates with existing automation architecture interfaces based on interoperable web services > Offers a cost effective out-of-the-box solution thereby reducing engineering costs > Supports today s leading improvement methodologies - Six Sigma and Lean Manufacturing

5 Ampla Express: OEE+E OEE is a well understood metric that can assist in the optimization of production processes (availability, performance and quality). However, this tested formula lacks an energy efficiency component. By considering energy, in addition to OEE, the effectiveness of your assets can be maximized. Ampla Express: OEE+E > Gauges OEE and displays it as a KPI for monitoring and improvement. When combined with the additional energy-related knowledge, asset optimization is achievable > Connects to multiple plant and business systems, collects required data and presents it as easy-tounderstand, real-time intelligence for productivity analysis, data mining, querying and reporting > Tracks OEE with energy over consumption events in the same context > Is a simplified, out-of-the-box application that can easily integrate with existing automation architectures Overall Equipment Effectiveness and Energy (OEE+E) is an option of Ampla Express. Optimize OEE Understanding OEE enables managers to optimize production processes. It facilitates the benchmarking of key production metrics, such as availability and performance, that, when influenced, can improve production efficiency. Availability considers actual operating time as a percentage of planned production time. Performance takes into account the rate of production, that is, actual units produced in a given time frame, compared with expected production. Stabilize energy usage Ampla Express: OEE+E enables operations managers to make continuous energy improvements by analyzing energy usage over production output. This is facilitated by setting energy efficiency as a KPI that compares target energy consumption with actual consumption. In addition, it links energy usage with actual consumption causes. With this information, it is possible to identify new savings opportunities, stabilize energy usage, order new equipment and improve operating procedures. By reporting on energy overconsumption events, Ampla Express: OEE+E breaks down complex issues into common causes and helps managers to achieve maximum asset optimization. Reduce Energy Consumption > Identify energy reduction opportunities by analyzing energy consumption data in production contexts such as operating crews, product lines, material grades and recovery rates > Identify potential energy waste conditions by capturing, summarizing and visualizing root causes > Make better informed decisions on viable energy savings using validated energy data Benefits at a glance Optimize OEE > Reduce plant stoppages > Identify and account for hidden slow running events > Reduce production inefficiencies > Increase asset utilization and equipment uptime > Decrease overall cost per production unit > Identify bottlenecks and deliver data on variations and stoppages OEE is tracked with energy usage over consumption events in the same context

6 Understand energy used in production Schneider Electric Industries SAS 35, rue Joseph Monier F Rueil-Malmaison FRANCE Tél. : +33 (0) Due to evolution of standards and equipment, characteristics indicated in texts and images in this document are binding only after confirmation by our departments. Ampla Express is a Trade Mark of Schneider Electric Industries SAS or its affiliated companies. Design: Schneider Electric 2012 Schneider Electric. All rights reserved. ART DIA6ED EN 03/2012