Industry 4.0 illustrated – Resource efficiency through digitalisation

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Digital and fully-automated processes boost resource efficiency for companies in the manufacturing sector. VDI ZRE’s new video uses Blechwarenfabrik Limburg to show how this works.

There, several management systems are used to digitalise production, while a business intelligence system is deployed to network these systems together, coordinate them and control them.

For example, a production planning system (PPS) directs production processes via a manufacturing execution system (MES), and an energy management system (EMS) analyses and regulates energy flows, compressed air and cooling water. All the data is collected by a business intelligence system (BI). If, say, the BI determines that more compressed air is being used for a certain number of tins, it will alert a technician to this. The technician can look for leaks straight away and fix them immediately, thereby saving energy.

The factory’s roof is home to more than 2,500 solar panels, which provide a third of the electricity required by the factory. What’s so special about this? The warehouse management system (WMS) automatically controls the flow of goods within the warehouse on the basis of the electricity available. This means that energy-intensive stock movements are carried out when the factory’s own photovoltaic equipment is producing particularly large quantities of electricity.

Furthermore, heat generated during production is used for heating and producing hot water.

All in all, this cuts the company’s expenditure on materials and energy by half a million euros a year. It also prevents more than 2,600 tons of greenhouse gases (CO2 equivalent) from being emitted, thereby making a successful contribution to protecting the planet.