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Energy Efficiency

The Energy Efficiency is the central KPI to indicate how close we are to the 'optimal' or minimum energy resource consumption. It is the starting point to assess current and past energy performance and to monitor the impact of any process improvements. There are several ways to define the efficiency. Here, we are comparing the total productive with the unproductive energy consumption by using the status of the Energy Consumer and the associated time category from the status mapping. The efficiency for Energy Resource j, between dates t1 and t2, is calculated as:

analysis-efficiency-kpi

where analysis-efficiency-energy is the total consumption for resourcej and where analysis-efficiency-productive represents a sum of the consumption over productive states that occured during the date range. For example, productive states could be "running", "working", or "producing"; unproductive states could be "idle", "waiting" or "maintenance".

The Energy Efficiency view includes several sections and charts related to this KPI:

analysis-energy-efficiency

Efficiency Overview

  • The gauge chart shows the total Energy Efficiency for the date range, with all applied filters.

    analysis-energy-efficiency-gauge

    The red "error" region is set by default to less than 30%; the yellow "warning" region is less than 70%.

  • The time chart shows the Energy Efficiency calculated in fixed time intervals. For date ranges less than or equal to 24 hours then the interval is 15 minutes; longer than 24 hours, but less than 7 days, then the interval is one hour; longer date ranges use daily intervals.

    analysis-energy-efficiency-chart

    The time chart is useful to detect date ranges where the efficiency is low and to start investigating the root cause.

State Overview

  • The donut chart shows the split in consumption according to each state that was active during the date range.

    analysis-energy-efficiency-state-gauge

    The total consumption is shown in the center. The tooltip shows the duration of each state.

  • This grouped bar chart shows the energy consumed in each state for each time interval. Each state is color coded according to the "Status" legend.

    analysis-energy-efficiency-state-chart

    The tooltip shows the consumption in that state during the specific time interval. This chart is useful to show when Energy Consumers were operating in unproductive states and to quantify the associated energy "losses".

Product Overview

  • The pie chart shows the split in consumption according to each product that was active in the date range and filters.

    analysis-energy-efficiency-product-gauge

    The tooltip shows the percentage consumption for each product.

  • The product table shows multiple KPIs for each product. The KPIs shown in the table can be selected using the "Configure" filter at the top right. The KPIs include

    • Unit: the count of number of units for each product
    • Actual energy
    • Optimal energy
    • Lost energy: the difference between the optimal and actual energy
    • Unproductive time
    • Efficiency for each product
    • Actual energy per unit
    • Optimal energy per unit

    analysis-energy-efficiency-product-table

    The table is useful to review numerical values for each KPI and identify any differences between product performance.

Energy Consumer aggregation

The Energy Efficiency is also calculated automatically at higher levels in the Energy Consumer hierarchy by aggregating the Energy Resource consumption across multiple Energy Consumers. The visualization is similar to the single asset view accept now the state variable is grouped according to its time category. This is so that the Energy Efficiency KPI can be calculated across machines that have different states and status mappings. In this example, the "Status" is shown as either Productive or Unproductive.

analysis-energy-efficiency-aggregation

In this way, the user could monitor the overall Energy Efficiency for a line or an entire plant.


Last update: January 15, 2025