Energy Monitoring System

Summary

Energy Monitoring System is a hardware + software solution designed for energy monitoring in production, accurately measuring electricity, water, steam, and compressed air used in each fabric roll or production piece. This enables precise, real-time energy monitoring instead of relying on estimated averages.

Need

• Measuring devices for electricity, water, steam, and air
• Centralized software for data collection and analysis
• Machine-level integration for energy monitoring in production per fabric roll

Existing Process

Currently, factories follow a manual estimation approach for energy monitoring: Utility readings are taken at department level over 24 hours and average consumption is calculated for overall usage. This average is used to estimate SAM (Standard Allowed Minutes) per article.

Proposed Process

The proposed energy monitoring system provides a data-driven approach: real-time energy monitoring at machine and process level, accurate measurement of utilities used per fabric roll, and automated data collection and analysis through software.

Limitations

• Based on assumptions rather than real data
• No precise energy monitoring in production at roll or process level
• High risk of SAM calculation and verification errors

Result

Reliable SAM calculation and verification

Transparent energy monitoring in production

Reduced waste and improved operational efficiency