In the context of Industry 5.0, production management is no longer focused solely on cycle times or finished product quality, but also on energy consumption analysis. With this objective in mind, Cugher develops solutions that make energy-related information easily accessible and understandable for operators. Through customized visualizations and seamless integration with supervisory systems, energy monitoring becomes a practical tool that supports daily operations.
Our solutions integrate advanced energy monitoring devices designed to ensure reliable measurements and accurate consumption control. Depending on the customer’s specific requirements and existing factory infrastructure, technologies from leading market players such as Siemens, Lovato, FRER, and Phoenix Contact can be integrated, ensuring maximum compatibility with existing plant systems.
ENERGY AS A PERFORMANCE INDICATOR
Once considered merely an operating cost, energy consumption is now recognized as a key performance indicator for production plants. Analyzing energy usage throughout the different stages of the production cycle — start-up, production, standby, format changeover, and shutdown — makes it possible to distinguish consumption associated with normal operations from avoidable energy use, helping identify anomalies and opportunities for improvement.
CORRELATING ENERGY DATA WITH PRODUCTION DATA
Energy data becomes truly valuable when analyzed alongside other production indicators such as output quantities, cycle times, machine status, and operating conditions. The objective is not simply to measure how much energy is consumed, but to understand when it is consumed and how it impacts productivity. This integrated approach supports decision-making based on objective and measurable data.
INDUSTRY 5.0: PRODUCTIVITY AND SUSTAINABILITY WORKING TOGETHER
Industry 5.0 promotes a production model in which technology and people operate in a fully integrated way. Within this framework, energy monitoring becomes a strategic tool for:
- Improving control over production processes
- Reducing waste and optimizing energy utilization
- Supporting the sustainability of manufacturing operations
Making energy consumption visible means transforming a technical parameter into actionable information that can be understood and utilized by production, maintenance, and management teams alike.
TECHNICAL TIPS
1 – Monitor High-Consumption Phases
Regularly tracking energy consumption during start-up, production, standby, and changeover phases helps identify the areas with the greatest energy impact.
2 – Compare Equivalent Production Runs
Analyzing similar batches or production runs makes it easier to identify operational variations and potential deviations in energy consumption.
3 – Analyze Consumption Peaks
Evaluating the frequency, duration, and context of consumption peaks helps identify situations that may require further investigation.
4 – Regularly Review Dashboards and Reports
Consistent analysis of available data facilitates long-term consumption monitoring and helps verify the effectiveness of implemented actions.
5 – Involve Plant Operators
The experience of personnel who use the equipment daily can provide valuable insights for correctly interpreting collected data and identifying potential areas for improvement.
In an Industry 5.0 environment, energy consumption monitoring transforms data into a practical decision-support tool. Making energy a measurable and easily interpretable parameter improves process control, increases production efficiency, and promotes more sustainable plant management.
