PLANT MANAGEMENT AND LEADERSHIP
Find the factors increasing production costs.
Review downtime, production rates and equipment energy consumption to prioritize improvement work.
Total production figures or an energy bill do not reveal where losses occur. Comparing investment options requires identifying the machine, product and period associated with a performance difference.
PLANT MANAGEMENT / EXAMPLE ANALYSIS
One cell. Three questions to guide improvement decisions.
Prioritization requires understanding which equipment consumes energy, under which operating conditions and what changed after the intervention.
01 / SOURCE
Does the measured power belong to the moulding machine or an auxiliary?
02 / CONDITION
Was the equipment producing, waiting or preparing for another batch?
03 / VERIFICATION
Did consumption change under comparable conditions after the intervention?
What can be analysed?
Examine cycles, stoppages and consumption by electrical feed together. Compare equivalent production periods before attributing a change to an intervention.
01
Available capacity
Distinguish downtime, cycle-time deviations and rejected output. Identify the loss limiting production-plan fulfilment before allocating resources.
02
Energy by equipment
Separate the consumption of the moulding machine and measured auxiliaries. Energy per part can be estimated when reliable production counts and documented allocation rules are available.
03
Phased investment
An initial phase can focus on one cell or technical question. The data collected and actual implementation costs inform subsequent investment decisions.
PLANT MANAGEMENT · FURTHER ANALYSIS
Which losses warrant further investigation?
Downtime, energy use and rejects affect production costs differently. Deciding what to measure first requires distinguishing physical losses, potential financial effects and the plant’s actual operating constraints.
How can misleading comparisons be avoided?
Distinguish potential capacity from confirmed sales, measured energy consumption from technically avoidable consumption, and total output from conforming output. Every project should establish how its impact will be verified.
Further questions: Data for productivity and cost analysis · Capacity losses from downtime · KERN IoP | ENERGY measurement
A PLANT-FLOOR EXAMPLE
Before drawing conclusions.
One cell consumes more energy than another. Before proposing a machine replacement, examine the product, actual output, auxiliaries included and idle periods. Total kWh alone do not show which cell performs better.
RELATED CONTENT
Energy measurement
Machine and cell consumption.
Productivity
Operating times, output and OEE.
TO INVESTIGATE FURTHER
Which data help identify productivity and cost losses?
The most useful data depend on the problem: cycle time, downtime, energy, quality or baseline conditions.
APPLICATION ASSESSMENT
Discuss an opportunity in my plant
We define equipment, indicators, responsibilities and comparison criteria. The proposal distinguishes hardware, software, installation, services and expansion conditions.
Describe your needs using the information available. Confidential documents are not required.
Applications
Engineering
Resources
PM Tec Engineering, through its Industry 4.0 division, KERN IoP.
Cota, Cundinamarca · Colombia.
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