Facing rising media costs, the need to optimize energy efficiency, and meet sustainability goals, manufacturing companies encounter significant challenges. SMART+ Media Monitoring is an innovative tool that not only addresses these issues but also enhances the competitiveness of production facilities.
Our system provides full control over media consumption, enabling real-time analysis, automatic reporting, and precise production cost summaries.
Challenges in media management and their solution
Challenges in the Manufacturing Industry:
- Rising media costs: Increasing energy and water prices are a significant issue for many companies.
- Energy efficiency optimization: Many facilities struggle with the lack of precise data needed to make informed decisions.
- Sustainable development: Reducing the carbon footprint and minimizing media losses are key objectives for many companies.
How SMART+ Addresses These Challenges:
- Accurate consumption data: Monitoring key media in real time.
- Cost optimization: Enabling loss reduction and improved operational efficiency.
- Simplified billing: Automatic reports allocating costs to facilities, products, and employees.
How does the SMART+ System work?
Complete Infrastructure: Meters, analyzers, sensors → SMART+ System → Access via browser, email reports, SMS alerts.
System Operation Steps:
- Data Centralization:
- Data from meters and measurement devices are collected in a single location, providing full insight into media consumption within the facility.
- The system supports various types of media, such as water, energy, steam, and other raw materials.
- Real-Time Analysis:
- Data is processed and analyzed continuously, enabling rapid detection of anomalies and real-time decision-making.
- Automatic Reporting:
- Technical Reports: Detailed data on system errors and monitoring.
- Production Reports: Calculations of media consumption per unit of product produced.
- Event Reports: Alerts on exceedances, allowing immediate response.
Key features and benefits of SMART+
Key Features of the System:
- Notification mechanism (SMS/email) for anomalies and failures.
- Platform for remote real-time media monitoring.
- Automatic generation of daily, weekly, and monthly reports.
- Optimization of tariffs and contract power, helping to reduce energy costs.
- Media consumption per unit of product, enabling precise cost calculations.
Benefits for the Client:
- Immediate control: Ability to respond quickly to events and detect losses.
- Accurate billing: Data assigned to specific facilities, products, and activities.
- Efficiency improvement: Reduction of production losses, such as air leaks or inefficient machine changeovers.
- Support for sustainable development: Reduction of media consumption and carbon footprint.
Use Case 1: reporting exceedance of declared power
Problem: The client was incurring financial penalties for exceeding power above 30,000 W.
Solution: The SMART+ system reacts immediately to declared power exceedances by sending notifications to key personnel.
Process Flow:
- The main meter records the power exceedance.
- The system detects the event and generates an alarm.
- Shift managers receive an SMS with instructions to reduce consumption.
- Management receives an email with a full event report.
Benefits:
- Elimination of financial penalties.
- Rapid response to critical events.
- Improved energy efficiency.
Use Case 2: monitoring energy consumption by facilities
Problem: The client was unable to monitor energy consumption on the production line without a separate meter.
Solution: SMART+ calculates energy consumption by differentiating readings from main and auxiliary meters.
Process Flow:
- Creating an object in the system (“Capacitor Production Line”).
- Calculating energy consumption as the difference between meters.
- Data is recorded every 15 minutes.
- Reports can be generated via the browser.
Benefits:
- Full control of energy consumption on selected production lines.
- Ability to analyze and optimize processes.
Use Case 3: Correlating media consumption with production volume
Problem: The client required a report correlating media consumption with the production of different product variants.
Solution: The SMART+ system automatically generates reports by integrating data from ERP and media monitoring.
Process Flow:
- ERP provides data on the number of products produced.
- The system monitors media consumption on production lines.
- The report combines production and media consumption data.
- The report is sent via email to responsible personnel.
Benefits:
- Automation of daily reporting.
- Accurate data for analyzing production efficiency.
- Ability to optimize processes based on precise information.
Why Choose SMART+?
- Full media control: Real-time data.
- Accurate billing: Automatic reports and summaries.
- Flexibility: Ability to adapt to the specifics of each facility.
- Sustainable development: Optimization of resource usage and reduction of losses.
Quote from the SMART AUTOMATION Team
Our SMART+ system is custom-designed for each facility, making full use of the existing measurement infrastructure. Thanks to the system’s nearly unlimited expandability, we offer solutions perfectly tailored to our clients’ needs — both visually and functionally.
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