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Overview
Client: A world leader in the food & beverage industry
Duration: 4 months
challenges
The client faced several operational inefficiencies and challenges related to utility management:
1. Inaccurate Data Entry: Manual data entry for water, energy, temperature, and relative humidity meters often resulted in inaccuracies due to human errors.
2. Excessive Paperwork: The reliance on numerous paper-based logbooks, check sheets, and audit reports was cumbersome and inefficient.
3. Inadequate Alerting Systems: There were insufficient alert mechanisms in place for meter failures or disconnections, leading to delayed responses.
4. Limited Meter Performance Visibility: The client struggled with limited visibility into the performance of meters located in remote areas of the factory.
Objectives
To address these issues, the project aimed to:
1. Implement advanced metering infrastructure capable of capturing real-time utility data, including water, energy, temperature, and relative humidity.
2. Ensure accurate measurement, data logging, and transmission capabilities for all meters and sensors.
3. Integrate advanced analytical dashboards to provide insights into utility consumption patterns, aggregated visual charts, trends, and alerts.
Solution implemented
We implemented the solution using Ignition’s platform, connecting over 50 flow meters, 30 energy meters, and 25 temperature and relative humidity sensors across more than 25 different process areas, and built a Unified Namespace (UNS). The functionalities delivered included:
1. Real-time Insights: Enabled real-time monitoring of utility data.
2. Workflow-Based Approvals and Alerts: Implemented a system for automatic approvals and alerts based on predefined workflows.
3. Analytical Dashboards: Provided comprehensive analytics dashboards, live trends, and production reports.
4. Robust Alert and Escalation System: Established a robust system for alerts and escalations via Email and SMS.
results achieved
Over the next three months post-implementation, the client observed significant improvements:
1. Improved Equipment Efficiency: The early detection of equipment malfunctions or inefficiencies led to a 10% to 20% improvement in equipment efficiency.
2. Environmental Impact: There were notable reductions in carbon emissions and the ecological footprint due to decreased energy and water consumption.
3. Real-time Monitoring: The availability of real-time dashboards, alerts, and notifications enhanced operational oversight.
4. Preventive Maintenance: Early detection of meter failures or disconnections enabled the implementation of proactive maintenance measures.
Conclusion
The centralized utility management system not only resolved the client’s initial challenges but also provided significant operational and environmental benefits. By leveraging real-time data insights and advanced analytical tools, the client was able to achieve higher efficiency, reduced environmental impact, and more effective maintenance strategies, setting a new standard for utility management in the food and beverage industry.