WAYS TO INCREASE OPERATIONAL EFFICIENCY AT MANUFACTURING PLANTS- APPLICATION OF IOT-A CASE STUDY

MANISH SAXENA, Joint Advisor,

Telecom Regulatory Authority of India,

Regional Office, Jaipur

PROBLEM: HOW TO INCREASE OPERATIONAL EFFICIENCY AT MANUFACTURING PLANTS

Customers

Needs to address

Manufacturing Plants

There are many ways, IoT can help in increasing operational efficiency in manufacturing plants e.g. inventory

control and supply chain management. But one of the greatest advancement may be made possible by the IoT is

energy management .• How to minimize and optimize

energy consumption

TRADITIONAL SOLUTION

•Energy is often one of the largest expenses for manufacturers. Traditionally , most of the plants managers obtain energy consumption data from monthly utility bills or energy monitoring tools with limited data points.•Monthly utility bills are delivered after a substantial period post the end of the billing cycle. Further they often report energy use for entire manufacturing plants. This information is of little use for plant managers for identifying waste or enabling reduction of consumption.

IoT Solution

• Using device connectivity enabled by IoT, manufacturers can track energy consumption patterns at the device level. A sensor /actuator is installed at each of the machinery part/ energy consuming component to remotely monitor and control the energy consumed by that manufacturing equipment/component .• Machinery energy consumption data is also collected through the sensors and devices send periodic message regarding energy consumed to the controlling station may be in the same premises or at remote location of IoT company. This data is analyzed to help optimize the energy consumption in manufacturing process.

IoT SOLUTION AND BENEFITS

Benefits

By tracking each piece of machinery on the floor, managers and executive get granular

visibility into energy consumption, actionable insight about waste, increased

operational efficiencies, impending equipment failures, regulatory compliance

etc. Resource Utilization: Real time energy profiles allow manufacturers to detect off-

hours consumption, optimize manufacturing production schedules and

identify anomalies.Benchmarking: Manufacturer can

benchmark similar piece of equipment to find out systems that are not functioning

properly to detcet hidden operational inefficiencies and energy waste.

IOT SOLUTION AND BENEFITS

Predictive Maintenance: Manufacturer gets alerts for service when service is needed based on recognized unusal energy usage,

thus avoiding the high costs equipment downtime.

Efficient Production: Same or greater outputs with more efficient energy use due

to optimal manufacturing processes.

Operational Efficiency and Profitability: Increased

operational efficiencies made possible by this IoT solution of

device level energy management immediately affects the bottom line for

manufacturers. For example using predictive maintenance manufacturers can eliminate machinery failure , which is

costly and its associated down time which may be even more costly. Moreover with device-

level energy consumption data made possible by IoT,

manufacturer can reduce their wasteful consumption and hence their energy spent.

IoT SOLUTION AND BENEFITS

Feature Requirement CommentNetwork Area • Wide Extended area of manufacturing

plants and control/monitoring centre at remote location require significant signal coverage

Spectrum • Dedicated Quality of service of transmission is a crucial factor

Battery Life • Short/ N/A Device may be charged by factory supply

Connectivity cost

• Medium Associated with the type of technology.

Module Cost • Medium/High Price may not be an issue in big manufacturing plants

Bandwidth • Medium Data needed to monitor energy use in various components may be moderate.LPWA 2G 3G

TECHNOLOGIES

MOST LIKELY BUSINESS MODELBusiness Model Revenue of the IoT

companyDevice ownership

Costs-saving sharing Recurring IoT company

• The IoT company installs, operate and maintain the monitoring and control equipments/system with no upfront fees.• The end user (manufacturing plant) pays for the equipment rental from the energy savings generated by the IoT solution.

OPERATIONAL ISSUES & POLICY TOPICS

Network coverage

Business Model

Global deployment &

taxationLegal

framework in Cost-saving

business model

Operational Considerations

Policy areas

Mechanism to assess savings

in cost

THANKS