Efficient Plant January 2020 - 26

feature | solution focus
analytics is embedded across the
and reporting of local energy usage.
architecture. This approach accomWe can see the history of spending
modates information technology (IT)
trends and receive a breakdown and
and the company's and third-party
description of how we are consumoperations technology (OT) equiping the energy we purchase. We can
ment and software. Operators are able
even make accurate predictions of
to view cloud-connected critical data
future energy costs and usage trends.
anytime, anywhere, from any device.
We estimate that this increased
Resiliency and visibility are improved
visibility has produced more than $6
through live sensor data, predicmillion in energy savings over the
tive analytics, and smart alarming.
past several years," said Labhart.
Operators also have access to experts
The entire Lexington factory floor
monitoring connected assets 24/7.
is populated with monitoring techEcoStruxure improves the agility of
nologies that issue alarms whenever
manufacturing organizations by
a production anomaly occurs. "If we
enabling key process owners to
experience a problem where a sensor
respond more quickly to market
fails to track, or a certain temperadynamics. By providing a collaborature is exceeded, an alarm condition
tive workspace that connects appliexists there at the edge," Lyczkowski
cations and analytics to machines on
explained. "We are now phasing in
Connectivity and integration have become a key focus and plant
the shop floor, the architecture allows
the ability to inform appropriate permodernization has directly opened the door to higher profitability
for
Schneider
Electric's
Lexington,
KY,
facility.
Photo
courtesy
teams to view combined intelligent
sonnel on their mobile devices (where
Schneider Electric
dashboards in real time.
they can be at home or anywhere in
"By making our existing infrastructhe world) to alarm conditions."
ture smarter, we are able to extract data
and determine whether a cylinder has
The addition of the new suite of
that was never available... and now use that
retracted inside the machine without ever
EcoStruxure tools has reduced paperwork
data to make the right decisions quickly,"
having to open the machine.
through digitization and dashboarding, and
said Steve Lyczkowski, Plant Manager. "We
"Utilizing augmented reality reduces
has enabled predictive analytics through
are now quite developed at the connectour mean time to repair by 20% on critical
data sharing. According to performance staed-products level. The push buttons, lights,
equipment," said Jeremy Elias, Manufacturtistics, rapid-alarm communication reduced
backlights, terminal strips, limit switches,
ing Engineering Manager. "This allows techtime spent doing paperwork by 90% and
photo eyes, RFID switches, and Magellis
nicians more time to perform more-producsystem downtime by 5%.
HMIs are all connected. If a technician or
tive active machine maintenance."
Modernizing this working facility, in
operator on the shop floor has a problem, I
The Lexington plant has also invested in
operation for more than 60 years, needed to
get an alert. This makes the lines more effidigitized energy-management tools. The
be done over time, requiring the Lexington
cient and I now have the ability to control
paint room, for example, has incorporated a
team to strategically balance the need to
core processes remotely," he said.
series of connected meters that monitor the
embrace new connected technologies with
Labhart and his team have deployed sevenergy consumption of all critical processes.
the needs of the business and a set operating
eral apps that have had a positive impact on
Meters gather the energy data and visualizabudget. The successful digitization evoluefficiency across the plant floor. One recent
tions are run on the data that reveal how to
tion required a step-by-step approach, taht
addition, the EcoStruxure Augmented Opmost efficiently use kilowatt hours based on
involved adding new EcoStruxure technoloerator Advisor, digitizes machine informathe type of metal that's running through the
gies individually where they would provide
tion in an augmented-reality format. The
line. The facility engineer uses the energythe greatest value and connecting them with
data is viewable from a standard portable
management tools to help achieve 3.5%
existing equipment. EP
tablet. For example, a maintenance technienergy savings yearly across the facility.
cian can walk up to a piece of equipment
"These tools provide us with monitoring
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26

| EFFICIENTPLANTMAG.COM

JANUARY 2020


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Efficient Plant January 2020

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Efficient Plant January 2020 - Cover1
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