As global energy demand continues to grow, manufacturers must work hard to maintain their sustainability responsibilities, while keeping up with technological advances and meeting the needs of consumers.

As the smart grid, there are varying definitions and perceptions of the future factory – arising from a more general ‘Industry 4.0’ concept. They all describe developing scenarios in which cutting-edge technology optimizes processes, monitors and maintains production systems, and improves efficiency.

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Improving energy management with data

Advances in data processing are central.

Sensors of varying complexity and scope are now used to dynamically monitor and measure machinery, plant, facilities, processes, and equipment. Digitally linked to other assets – as well as management systems and data repositories – they gather and communicate information for constant analysis.

These sensors can have wired or wireless connections which feed operational variables such as temperature, power usage, vibration, pressure, and other markers into cloud-based management platforms. Manufacturers use this to inform dynamic decision-making around production efficiency.

For example, if a particular component within a specific machine or process element has failed and is starting to impede production performance or waste power, real-time analytics can trigger alarms to flag this immediately for investigation.

This intelligence allows manufacturers to better control energy use, as well as fine-tune maintenance planning. A further benefit is the ability to focus maintenance budgets appropriately, avoid over and under-servicing, and predict equipment failures before they occur. Data-driven insight also offers increased clarity around plant and machinery lifespan, mitigating production downtime risks.

A further important advance is the rise of the digital twin – a ‘living’ digital replica of a connected asset – that promises further energy efficiencies, as well as design advantages.

Understanding digital twin standards

Manufacturers can use a digital twin to refine design efficiencies relating to a product’s energy consumption, through dynamic simulation and modelling, to predict and measure power wastage. Performance data from products already in use by consumers can also be fed back into the twin to help future design iterations.

Digital twin standards creation is active in this area. Currently, in development, the BS ISO 23247 series is designed to provide an overarching framework for digital twin manufacturing, while PD ISO/TR 24464 will focus on the relevant visualization elements.

The role of energy management standards

Further efficiencies – as well as improved supply and demand balance – can be unlocked by manufacturers with micro-grid or renewable generation capability selling back their excess energy. It has been proposed that blockchain could provide an independent, swift and practical means of achieving this.

Manufacturers can use internationally recognized energy management standards to help integrate these technical advances. Chief among them is BS EN ISO 50001, which provides a framework by which companies can implement an energy management system to help reduce cost, comply with legislation and improve sustainability. It also helps organizations identify future supply risks for mitigation. Any effort to improve energy efficiency in a manufacturing context must work in concert with wider sustainability strategies. BS EN ISO 14001 empowers companies to create an environmental management system.

As well as improving sustainability it promotes cost-savings, improved brand reputation, and employee engagement. Taking a standards-based approach in this way builds resilience against energy supply uncertainty, as well as the ability to adapt to change. Integral to every sustainable operation is the circular economy concept which seeks to decouple economic growth from resource consumption and ease pressure on the planet. It also promises fresh economic and employment opportunities. BS 8001 offers a practical framework and guidance for organizations looking to implement circular principles.

Finally, for those manufacturers looking to invest in their own wind generation capabilities, BS EN 61400-25-1 describes overall principles for monitoring and control of wind power plants. Once a company has an optimized and energy-efficient manufacturing operation in place, and is truly balancing out any negative environmental impacts, it can use PAS 2060 to demonstrate its carbon neutrality.

Add these key energy management standards to your collection to help your organization manage energy efficiency in its supply chain.

Discover BSI Knowledge

As the pressure builds for all manufacturing businesses to achieve net zero, knowing which standards can help you and how to share their guidance within your organization can seem like a huge challenge. With a BSI Knowledge subscription, you will have the flexibility and visibility to manage the key standards you need in order to start your journey to net zero with confidence. Build your own custom collection of standards, or opt for access to one of our pre-built modules and keep up-to-date with any relevant changes to your standards strategy. Request to learn more.