Solution Brief
Lower energy usage and spend in heavy industries by optimizing energy costs.
The need to use less energy is becoming critical to manufacturers, especially those in heavy industries, because of their energy-intensive processes. The cost of energy has been volatile, and according to the International Energy Agency, “… energy markets, geopolitics and the global economy are unsettled and the risk of further disruption is ever present.”
Manufacturers must also meet the carbon reduction demands of external stakeholders, including investors, customers and governments. Investors are backing companies focused on environmental, social and governance (ESG) standards and divesting those with poor ESG ratings. Customers prefer to purchase sustainable products. Global governments continue to rapidly develop policies and regulations supporting sustainability. Therefore, manufacturers need to employ energy optimization to use less energy and successfully navigate these challenges.
High energy costs pose a serious burden for heavy industries. With SAS advanced analytics, manufacturers quickly realize significant energy cost savings.
Energy security and limited renewable energy
Heavy industries often require a steady, consistent supply of nonrenewable energy sources, which makes energy security and access to renewable energy a challenge. SAS reduces the consumption of traditional energy sources to support the transition to 100% renewable energy.
Regulations and downtime
Manufacturers must comply with changing emissions regulations without affecting operations or causing plant shutdowns. SAS helps lower energy use and carbon footprint without affecting operations or downtime.
Complexity
Reducing variability in combustion processes can be complex. SAS advanced analytics simplifies the process by identifying areas where to tweak processes for greater stability.
Reporting
Manufacturers need trustworthy reporting to measure and track progress effectively and avoid greenwashing accusations. SAS delivers trustworthy AI that makes it easy to accurately measure and track improvement.
Using SAS for energy optimization enables manufacturers to:
(Reduce energy costs and usage while maintaining quality and yield; Create a more stable process by reducing variance; Increase overall process understanding)
Manufacturers that reduce energy use will realize positive effects on their revenue and competitiveness. They must find a way to use less without disrupting production. Forrester predicts that “over 50% of manufacturers will have to slow electrification as the grid fails to keep up” in its Predictions 2025: Smart Manufacturing and Mobility report. We approach the problem with our SAS energy cost optimization accelerator, which uses SAS Analytics for IoT, to help you:
Reduce energy costs and usage
Provide engineers with the missing insights needed to improve key process parameters by analyzing the relationship between them and energy consumed so you can lower energy usage, energy costs and CO2 certificate spending.
Identify optimum shift parameters
Use advanced analytics models for production runs to dynamically compare current and historical runs and show the drivers of energy consumption.
Minimize energy consumption while maintaining quality
Determine the exact setpoints that should be applied to the process using a set of mathematical optimization solvers.
Achieve capacity, capabilities and possibilities – faster
Reduce carbon footprint and help meet ESG requirements.
SAS enables you to discover unrealized opportunities from your existing equipment – while reducing interruptions to production and monitoring and repairing quality issues. SAS anomaly detection algorithms look at the entire asset, not just one specific sensor. The results pinpoint the main issue so you can quickly discover what’s wrong via root-cause analysis. SAS helps manufacturers:
Isolate and quantify the effects of anomalous factors that affect critical equipment
Run models in real time and get predictive alerts on maintenance issues
Employ root‐cause analysis tools and take corrective action quickly
Predict downtime to avoid unnecessary preventive maintenance and provide only the maintenance needed to deliver peak performance
Award
The Energy Cost Optimization solution from SAS recently won product of the year, an award that honors the best, most innovative products powering the Industrial Internet of Things. Our award-winning solution helps manufacturers accelerate time to value and provide significant energy cost savings.
