31%
Idle Energy Share Identified
19%
Electricity Cost Reduction
-24%
Energy per Unit Produced
22
Submeters Installed
The Challenge
Electricity was the third-largest line item on the plant's P&L, but management had no visibility into which machines or production lines were driving the cost. There was a strong suspicion that machines were drawing significant power during unplanned downtime and idle periods between jobs, but no data to confirm or quantify it. Monthly utility bills gave a single total — nothing more.
The Solution
Deployed Energy Management on MACHHUB with 22 smart submeters installed at individual machine circuit breakers via Modbus RTU. Energy readings were synchronised with OEE data so the system could automatically separate productive energy consumption from idle and downtime consumption. Automated daily and weekly reports show energy cost per unit produced, broken down by machine, shift, and job.
The Result
Analysis revealed that 31% of total electricity was being consumed during non-productive periods. Targeting the three highest idle consumers — two large hydraulic presses and a CNC machining centre — with automatic power-down rules and operator discipline procedures led to a 19% reduction in total electricity expenditure within six months. Energy cost per unit produced fell by 24%.
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