Learn how the Smart Manufacturing Data Hub has helped companies on their digitalisation journey

OS Doors Leverages Energy Insights Data to Drive a Sustainability Strategy

SITUATION
OS Doors has experienced significant growth which has results in a substantial rise in energy consumption. The goal was to identify opportunities to optimise energy efficiency, reduce costs and ensure long-term sustainability in their operations. 

SOLUTION
An Energy Insights solution was developed to help optimise energy use. A year of energy data was provided from OS Doors from a single electricity meter along with shift patterns and tariffs. Key insights found that on Fridays, consumption dropped after morning shifts but rose later due to overtime. 

IMPACT
This solution has provided OS Doors with insights into their energy consumption during productive and non-productive time in the factory. OS doors will use the insights as a baseline for their upcoming sustainability strategy and are looking at green energy and methods to reduce carbon emissions.

IoT intelligent wireless monitoring of Precast Concrete Equipment

SITUATION
When assessing the condition of their manufacturing systems, Macrete's maintenance staff found that a piece of rotating equipment might appear serviceable externally but could have hidden internal failure issues.

SOLUTION
Macrete decided to undertake a project with the Smart Manufacturing Data Hub that would allow them to monitor assets in real time, using intelligent, wireless, IoT sensors to target machine downtime and energy usage. An easy-to-use dashboard IS accessible in real-time from any location, with alerts set up to allow the team to identify patterns and establish best practices.

IMPACT
By setting up alerts, the team were able to detect when abnormal vibrational activity occurred, allowing Macrete to conduct timely maintenance, mitigating the risk of equipment failure and unplanned downtime.

Scott & Fyfe assessed their current energy consumption and build clear data visualisations

SITUATION
Scott & Fyfe wanted to assess their current energy consumption, measure the impact of energy efficiency measures already implemented, and identify further opportunities for energy savings where possible. 

SOLUTION
Using the “Energy Insights” dashboard, the SME was able to see that 68% of their energy consumption was made up of “base consumption”, i.e. energy that is consumed by equipment that is always switched on.

IMPACT
Using the “Energy Impact” dashboard to compare the time periods from April 1, 2022, to January 31, 2023, to the same months of the subsequent year, the SME was able to measure a reduction in electricity consumption of over 1GWh (-37.4%).

Specdrum implement sensor technology and build clear data visualisations

SITUATION
Specdrum had to collect and analyse vast amounts of data manually which they found difficult to do in a timely and efficient manner resulting in slow response times to problems and issues revealed by data in the processing plant. 


SOLUTION
The SMDH team liaised with Specdrum to install digital and data solutions including the monitoring of power, air quality, oil usage, temperature and pressure. A dashboard now enables clear data visualisations for the team to monitor. 


IMPACT
Specdrum can now access real-time data visualisations from several areas of their factory. The automatic alert system from the dashboard ensures management are promptly notified of any potential problems within the factory.

Data Analysis project with AXON Power & Control Inventory

SITUATION
Axon had no automated data collection processes. All data were manually inputted into an information system called SAP, which was custom-designed for Axon's requirements.

SOLUTION
Data analysts conducted a thorough scan of the data, leading to visualisations of graphs and charts that facilitated the identification of patterns and trends assembled into a dashboard for Axon's review.

IMPACT
Axon successfully achieved their goal of reducing the number of stock items in their database by eliminating inventory listed as no longer required or utilised in orders empowering them to have optimal minimum and maximum stock thresholds.

Uform utilises the Smart Manufacturing Data Hub's Energy Insights for detailed insights and trends in energy usage 

SITUATION
Uform's half-hourly energy data collected over four years was analysed using SMDH's Energy Insights tool. SMDH were able to generate detailed insights and trends in energy usage on a daily, weekly, monthly and yearly basis. 

SOLUTION
Uform was provided with three energy dashboards allowing them to pinpoint areas for energy reduction. The analysis helped identify energy-intensive periods and evaluate the effectiveness of various interventions. 

IMPACT
Building on the success of this initial project, Uform have engaged with SMDH's Lighthouse partners, Devtank and Output Industries to explore the potential of real-time monitoring for further enhancing data-driven insights, energy consumption and resource efficiency within the factory.

Terex (Dungannon) recognises the critical importance of minimising energy consumption.

SITUATION
Terex sought to lower the effects of escalating energy costs and enhance sustainability. Terex was interested in exploring ways to better understand when, where and how energy was being used, as well as to identify opportunities for reduction.


SOLUTION
Terex and SMDH conducted an energy consumption investigation, capturing data on usage, shift patterns, and tariffs. The information was uploaded to MDEP, enabling Terex to analyse visual dashboards and extract insights for factory improvements.


IMPACT
The solution provided to Terex enables them to investigate their energy usage and would also allow the company to compare their energy consumption across other manufacturing sites. 

Ryobi utilises the Smart Manufacturing Data Hub to unlock value from their data

SITUATION
Ryobi has ambitious low carbon targets and want to get better insights from their energy consumption and production data to identify areas where energy could be saved.

SOLUTION
A dashboard was developed to combine data from Ryobi's electricity meters for two different die cast machines with production output and OEE data for the same machines. 

IMPACT
Ryobi were very pleased with the dashboards provided by the Smart Manufacturing Data Hub and have realised the value of combining their submeter data alongside production data to establish more insights on key metrics allowing them to invest in an energy platform.

Ritchie Precision makes significant strides in energy consumption management, with SMDH Energy Insights.

SITUATION
Ritchie Precision were looking to make changes to be able to run their factory as efficiently as possible, reduce consumption and thus reduce the cost of its increasing energy bills.

SOLUTION
Ritchie Precision uploaded their meter, shift and tariff data into the online data sharing platform where the Data Science team were able to access and analyse it. 

IMPACT
Ritchie Precision implemented behavioural changes turning off machines and a shift change to reduce their energy usage. Ritchie Precision have repeatedly resubmitted updates to their data and have been able to track the reduction in their energy consumption as a result.