Energy cost is one of the largest operating expenses for most manufacturers. Improving energy

efficiency can result in a huge reduction in operating costs and gains in profitability. Designed for

manufacturing operations, Schneider Electric’s Energy Performance solution integrates power and

energy management into overall business performance, enabling users to identify critical energy

efficiency gaps and electrical performance issues through improved operational visibility. With clearer

and earlier visibility into energy and power quality performance, Energy Performance improves your

competitive edge through reduced energy spend and improved sustainability.

software.schneider-electric.com/energy-performance

Reduce energy spend and optimize equipment performanceEnergy Performance for Manufacturing

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Energy management for manufacturing plant

The need for effective energy management in manufacturing plants

Over the past years, environmental awareness and regulations have increased significantly. The cost of energy continues to rise while aging electrical infrastructure increases the risks of electrical failures and adds unnecessary indirect costs to overall production. As a result, companies are becoming more focused on energy sustainability, equipment efficiency and reliability. Improving energy efficiency can lead to a significant boost in profitability as energy is one of the largest operational costs in a manufacturing plant.

Monitoring energy consumption and transforming energy data into relevant contexts are the foundation for effectively optimizing energy consumption. Manufacturers have often failed to deploy adequate energy metering devices at production lines, limiting the effectiveness of their existing energy management solutions. Besides, the different software systems that have been implemented to address various areas of production tend to create data silos in the plant. Combining these data silos with energy data to provide relevant contextual insights is a complex challenge. The availability of energy data and a solution’s ability to unify data from disparate sources are crucial to generating useful energy KPIs for energy management.

Introducing Energy Performance for Manufacturing

Based on Schneider Electric’s industry-leading power and energy management software platform, Energy Performance is a complete solution that converts data from disparate sources into actionable information, empowering manufacturers to reduce energy costs, monitor power quality and improve equipment performance. Its modular design allows companies to get started quickly to meet immediate needs, and the scalable solution can easily be expanded to meet evolving energy management needs.

software.schneider-electric.com/energy-performance | 3Industry Solutions

Energy management for manufacturing plant

Energy Performance combines powerful data acquisition and analysis technology with easy-to-use software interfaces, simplifying energy cost management, maintaining production uptime and maximizing asset performance.

At the Connect and Collect layers, power and energy data is collected directly from hardware devices such as Schneider Electric’s intelligent power meters, PLCs, DCS, breakers, relays, active harmonic filters, power factor correction systems, and fault detectors. Additional process and production data can also be acquired from any data source including Historian and MES databases.

At the Analyze layer, the combined energy and production data is synchronized and processed through the Energy Performance platform, turning it into process energy intensity information that enables tracking of energy usage in the operations and production contexts. In addition, the platform provides easy access to information about electrical system, power quality and equipment performance.

At the Act layer, pre-defined parameterized reports and configurable dashboards provide the energy information visibility in context with plant operations, delivering actionable insights to all stakeholders. This visibility enables users to optimize energy usage and reduce unnecessary waste while ensuring high power availability, avoiding unplanned downtime and maintaining optimum equipment performance. This information can also be used to document and baseline projects for energy use reduction, operational efficiency improvements and asset health optimization, becoming an essential part of the enterprise’s continuous improvement programs.

Energy data with operational context• Energy Consumption per batch / unit• Energy Consumption per production state• Energy Consumption per product

Power and electrical equipment monitoring• Monitoring of any electrical equipment for harmonics and potential power trip• Monitoring of electrical network quality

Real-time Dashboards and Reporting

ACT

Energy Performance for manufacturing

ANALYZE

COLLECT

CONNECT

Process & Production Data Energy Data(WAGES)

EnergyMeters

Historian

• Energy Spend• Unplanned Downtime• Equipment Performance

• Production Information• Energy Information• Non-instrumented Data• Online Process Data

• Data from various processes• Data from various devices

Power Monitoring Expert

MES Database

ProcessOrder

OperationsShift

Production State

Energy Performance – a comprehensive energy management solution

software.schneider-electric.com/energy-performance | 4Industry Solutions

Energy management for manufacturing plant

Features and Benefits:

1. Comprehensive energy monitoring system: Enable energy data disaggregation through integrating production and energy data with a full range of Schneider Electric’s smart meters, optimizing energy consumption and reducing unplanned downtime through improved asset reliability. Features include energy cost allocation, demand and power factor management, capacity management, power quality awareness and compliance, electrical and mitigation equipment monitoring. Benefits: Monitor energy performance as a whole from energy supply, demand, maintenance, operation to consumption. Uncover full range of improvements to reduce energy consumption.

2. Reduce energy costs through context-driven insights: Identify energy optimization opportunities by uncovering co-relations between peak energy demand and plant data with context driven insights, enabling manufacturers to proactively manage and optimize their energy usage. This also enables companies to allocate energy costs across manufactured goods, production lines, operations shifts, departments or processes more accurately, enabling benchmarking of energy performance for optimization. Benefits: Reduce energy costs, enable sharing of best practices and increase ease of establishing energy improvement initiatives with actual reduced energy usage outcomes.

Energy load trends allow quick identification of energy efficiency gaps

Enabling energy awareness through a comprehensive monitoring dashboard

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Energy management for manufacturing plant

3. Optimize equipment utilization: Extend equipment lifespan and reduce unplanned downtime due to power trips or harmonics by revealing abnormal equipment behaviors with unusual energy usage patterns, enabling the facility or maintenance team to identify root causes from electrical source to electrical and production equipment, and to rectify them before costly failures occur. Benefits: Improve ROI on operating assets and reduce unplanned downtime

4. Improve electrical network reliability: Monitor power network quality in real-time, generating notifications and alerts for abnormal power operations, enabling the facility or maintenance team to identify root causes from the electrical source to electrical and production equipment, and to rectify the problems before damaging any sensitive electrical equipment, causing production stoppages. Benefits: Improve ROI on electrical assets and reduce unplanned downtime

Extend equipment lifespan through monitoring of key electrical parameters

Dashboard monitoring of power network quality Dashboard monitoring of overall electrical capacity

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Energy management for manufacturing plant

5. Self-configurable KPI dashboards: Support operational flexibility in responding to changes in business environment and providing an extensive set of user-friendly reports and dashboards for analysis. The highly intuitive interface is designed with operations personnel in mind; dashboards are configured via a point-and-click user interface. Benefits: Shorten learning curve for stakeholders, reduce total cost of ownership and system maintenance, accelerate the benefits realized from energy improvement projects and maximize the reach of energy-related information.

Self-service KPI console improves system flexibility

software.schneider-electric.com/energy-performance | 7Industry Solutions

Energy management for manufacturing plant

1. Applications may require add-ons. Please contact your local sales for more details.

Energy Performance applications1 include:

Reducing energy cost

• Energy monitoring: Track energy usage throughout the facility to understand consumption patterns; energy usage by operations, batch, shift, and equipment state can be measured and used as a baseline to establish an effective energy reduction plan with realistic targets. Benefits: Enable energy consumption awareness, which is the foundation of all energy conservation programs.

• Energy usage analysis: Identify, correct and prevent excess energy consumption and waste. Identify a golden batch in terms of energy consumption. Determine the factors contributing to high energy usage. Monitor process energy and track energy intensity KPIs to maintain a high degree of energy efficiency. Benefits: Effectively manage energy as a variable cost in your bills of material, enabling energy cost to be a business driver.

• Utility bill verification: Proactively check your utility bills for billing errors with a shadow meter and automated billing reports that replicate your utility bills. Benefits: Allows comparison of utility bills to prevent over-charging mistakes.

• Demand management: Determine the loads and operational conditions leading to high demand levels. Adjust operations to minimize peak demand for every billing period. Benefits: Avoid unnecessary demand penalties or charges on your utility bill.

• Power Factor management: Install and operate Power Factor correction equipment to reduce Power Factor penalties or charges on your utility bill. Benefits: Improve Plant Power Factor and maintain high power efficiency levels.

Improving electrical system reliability

• Power quality monitoring: Identify electrical issues and respond quickly to power-related incidents. Determine the source of electrical disturbances whether from the grid or an internal power network. Benefits: Reduce unplanned downtime and maintain quality power distribution throughout your facility.

• Power event analysis: Identify root causes of downtime and equipment problems from in-depth insights, enabling corrective actions to mitigate power quality issues and prevent future power-related problems. Benefits: Improve overall operational reliability and power availability.

Improving equipment performance

• Electrical capacity management: Identify electrical equipment capacity issues. Safely maximize the loading of existing electrical infrastructure and support electrical distribution infrastructure planning. Benefits: Optimize electrical equipment performance without increasing risks of overloading.

• Equipment performance: Proactively monitor transformers, breakers, generators, inverters, and UPS devices to ensure healthy operation and assist with preventative maintenance schedules. Benefits: Reduce unplanned downtime through actionable insights into the state of the equipment.

Energy Performance helps manufacturers to significantly reduce annual energy consumption and unplanned downtime, enabling them to gain the next level of operational efficiency.

Energy management for manufacturing plant

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Business Value of Energy Performance

Energy Performance helps you improve operational efficiency and lower costs.

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© 2017 Schneider Electric Software, LLC. All rights reserved. Life Is On Schneider Electric is a trademark and the property of Schneider Electric, its subsidiaries and affiliated companies.PN SE-0288 Rel. 09/17

Industry Solutions

Extend equipment performance and

lifespan through early detection of potential

harmonic issues

Improve collaboration and energy

performance visibility of the entire plant

Enable compliance with power quality and energy

standards such as ANSI/IEEE and ISO 50001

Reduce operational costs, energy consumption and carbon footprint through

tracking energy consumption, uncovering savings

opportunities and accurately allocating costs

Manage energy as a variable cost, with energy in

context with production, enabling the addition of

energy consumption in the Bill of Materials

Reduce unplanned downtime by providing early warning of potential power

network issue that can disrupt production

Customer FIRST Software Maintenance and Support Program

Our Mission: Your Success

Energy Performance offers the award-winning Customer FIRST Software Maintenance and Support Program. Customer FIRST is a flexible portfolio of services that help protect and extend the value of your Schneider Electric Industry Solution across its entire lifecycle. A Customer FIRST Agreement establishes a formal service relationship with Schneider Electric, enabling access to the latest software upgrades and providing expert technical assistance, optional services, and self-help tools to help you improve your operational effectiveness.

For more information on Customer FIRST for Industry Solutions, please visit: software.schneider-electric.com/support/customer-first

For more information, please visit: software.schneider-electric.com