VIPA Green Solution. in accordance with DIN EN ISO

Transkript

1 VIPA Green Solution in accordance with DIN EN ISO

2 VIPA GREEN SOLUTION high energy consumption intensive hight operation poor equipm From 2013 the implementation of a fully operational energy management system has been a necessary condition for energy and electricity tax reduction according to the apportionment of Renewable Energy Sources Act (EEG). Companies with a total energy consumption of more than 1 GWh per year are already affected by this. A conscious use of energy is becoming increasingly important, not least for the protection of our environment. Increasing energy costs form a large part of the operating costs and reduce profit. In almost all enterprises however there is massive savings potential in energy usage. But it is also possible to save electricity and energy by organizational measures. One task of VIPA GREEN SOLUTION is to work out savings potential and reduce costs. Energy management Load management The spectrum of VIPA GREEN SOLUTION consists of four modules that can be individually adapted to requirements and demands quickly, easily and safely. Plant information system ERP/SAP Top Floor and Shop Floor

3 ent effectiveness Our service We offer an energy management system, which functions simply and reliably, with the added value of advice, products and solutions as well as implementation through VIPA from a single source. This energy management system enables very easy certification in accordance with DIN EN ISO or DIN EN Your advantages Your energy costs will rapidly reduce. Your processes will be organized and this allows energy efficient work. Efficient, intelligent, tailor-made that s the way it has to be in today`s production. Reducing costs Increasing energy efficiency Optimizing production Increasing transparency Being economical and sustainable Optimizing processes within a closed control circle Connecting the machines and plants of your production to your management system The 4 modules of the VIPA Green Solution Energy management (according to DIN EN ISO 50001) Energy management Energy monitoring Energy measurement Load management Energy controlling Intelligent process control Energy adaptation according to your process Intelligent conservation of resources Plant information system Overall equipment effectiveness / O.E.E Core error analysis Preventive maintenance Quality management Factory data recording ERP/SAP Top Floor and Shop Floor Integration in SAP Structuring a transparent communication between fi eld, process, installation and enterprise level Complete traceability from raw materials up to end product

4 von xx.xx.xxxx bis xx.xx.xxxx Energy management SQL data base VIPA EnMS Ethernet TCP/IP VIPA Energiemanagement Mess-/Kostenstelle 1 Mess-/Kostenstelle stelle 9 Mess-/Kostenstelle 2 Mess-/Kostenstelle 10 Mess-/Kostenstelle 3 Mess-/Kostenstelle 11 Mess-/Kostenstelle 4 Mess-/Kostenstelle 12 Mess-/Kostenstelle 5 Mess-/Kostenstelle 13 Mess-/Kostenstelle 6 Mess-/Kostenstelle 14 Leistung: xxx kwh Mess-/Kostenstelle 7 Mess-/Kostenstelle 15 Öl: xxx m³/h Mess-/Kostenstelle 8 Mess-/Kostenstelle 16 Gas: xxx m³/h Datum Trend 1-4 Trend 5-8 Trend 9-12 Trend Berechnung en Einstellungen Examine your energy efficiency The energy prices increases inexorably, economy pays off more and more. Scientists of the Fraunhofer Institute for System and Innovation Research found out, that most enterprises could reduce their energy costs by at least 10 to 20%. Renewable Energy Sources Act (EEG) The so called eco-tax discount is essential for survival for energy intensive production plants. By the end of 2015, they will have to have introduced an energy management system. Only then will they continue to benefit from this tax reduction. In 2012 this tax reduction was extended by the Input Energy meter Electric meter Gas meter etc. German Federal Government to This will cost the state 2.3 billion per year. In return the German economy has to show an annual energy efficiency increase of around 1.3%. Performance An energy management system, like all other well-known management systems, consists of a PDCA cycle. After the introduction of an energy management system that was defined according to PLAN- DO, our solution provides continuous data for your CHECK- ACT cycle. See diagram! Act Optimizing PLAN Planing VIPA EnMS Check Checking DO Implementing How does it work in practice? In the smallest case scenario this solution looks like this: a control unit for recording, logging and displaying the energy consumption is placed directly on the machine or system. The interfaces for measuring the energy consumption are detected via distributed decentralized I/O modules. The existing energy meters and measurement devices continue to be used as much as possible. Output Display Documentation Logging

5 Mess-/Kostenstelle 1 von xx.xx.xxxx bis xx.xx.xxxx Load management SQL data base ERP/SAP PC VIPA EnMS Ethernet TCP/IP VIPA Energiemanagement Mess /Kostenstelle 1 Mess-/Kostenstelle stelle 9 Mess-/Kostenstelle 2 Mess-/Kostenstelle 10 Mess-/Kostenstelle 3 Mess-/Kostenstelle 11 Mess-/Kostenstelle 4 Mess-/Kostenstelle 12 Mess-/Kostenstelle 5 Mess-/Kostenstelle 13 Mess-/Kostenstelle 6 Mess-/Kostenstelle 14 Leistung: xxx kwh Mess-/Kostenstelle 7 Mess-/Kostenstelle 15 Öl: xxx m³/h Mess-/Kostenstelle 8 Mess-/Kostenstelle 16 Gas: xxx m³/h Datum Trend 1-4 Trend 5-8 Trend 9-12 Trend Berechnung en Einstellungen Intelligent load management In general the definition of load management is the avoidance of load peaks and consumers being cut off. But what if you require exactly these for your production? This is exactly where our intelligent load management comes in! An assessment can only be usefully made when an order comes up and a statement on the delivery time is included. Certainly you want to, and have to, save energy and fully use your available capacity but on the other hand supply your customers on time. So the problem results from the fact that machines, which are required can`t simply be shut down because of a load peak. An intelligent control of production is essential! Adequate energy supply reduces peak loads that are avoidable by planning or mostly by a short time displacement. By suitable recording and controlling of machines and systems as well as a feedback to the machine and plant operator can save additional energy here. In addition a display device motivates you to save energy when you see what effect it has. How does it work in practice? The module energy management is extended by an interface to the ERP system which intelligently connects the energy consumers. Input Energy meter Eletric meter Gas meter etc. + Status of the plant or machine + Order from the ERP system Output Intelligent connecting of the energy consumers Display Documentation Logging

6 Mess-/Kostenstelle 1 von xx.xx.xxxx bis xx.xx.xxxx Plant information system SQL data base ERP/SAP PC VIPA EnMS Ethernet TCP/IP VIPA Energiemanagement Mess /Kostenstelle 1 Mess-/Kostenstelle stelle 9 Mess-/Kostenstelle 2 Mess-/Kostenstelle 10 Mess-/Kostenstelle 3 Mess-/Kostenstelle 11 Mess-/Kostenstelle 4 Mess-/Kostenstelle 12 Mess-/Kostenstelle 5 Mess-/Kostenstelle 13 Mess-/Kostenstelle 6 Mess-/Kostenstelle 14 Leistung: xxx kwh Mess-/Kostenstelle 7 Mess-/Kostenstelle 15 Öl: xxx m³/h Mess-/Kostenstelle 8 Mess-/Kostenstelle 16 Gas: xxx m³/h Datum Trend 1-4 Trend 5-8 Trend 9-12 Trend Berechnung en Einstellungen With the introduction of a plant information system the entire production process can easily be controlled. You quickly realize whether a delivery date can still be kept or if a fault in the machine or system has occurred, which needs to be remedied quickly in order to deliver the required quantities on time. Furthermore you can achieve a paperless production by ensuring all required information, tools and raw parts are where they are needed just in time. This reduces cycle times and increases efficiency. Critical company data is available for authorized persons anytime and anywhere. Thus an effective and cost saving information flow is guaranteed. A trouble free communication between different departments is possible by using simple methods. Security mechanisms provide optimal access protection and prevent unauthorized access to data. It consists of the following modules MDE Error reduction, overall equipment effectiveness, core error analysis TPM Preventive maintenance, failure mode and effects analysis (FMEA) BDE Order processing time, production status of the current order QS Test cycles, test plans, etc. integrable How does this work in practice? The module energy management and the module load management are extended by the functionality of a plant information system. It can be installed on our operating device, a Touch Panel from VIPA. If several machines or plants require such a system a server solution can easily be retrofitted. Input Energy meter Electric meter Gas meter etc. Status of the plant or machine Order from the ERP system + Detection of faults + Detection of good and bad parts Order from the ERP system Output Overall equipment effectiveness Production status messages Intelligent connecting of energy consumers Display Documentation Logging Availability Performance Quality

7 Mess-/Kostenstelle 1 von xx.xx.xxxx bis xx.xx.xxxx ERP/SAP Top Floor and Shop Floor SQL data base ERP/SAP PC AIS server VIPA EnMS Ethernet TCP/IP VIPA Energiemanagement Mess /Kostenstelle 1 Mess-/Kostenstelle stelle 9 Mess-/Kostenstelle 2 Mess-/Kostenstelle 10 Mess-/Kostenstelle 3 Mess-/Kostenstelle 11 Mess-/Kostenstelle 4 Mess-/Kostenstelle 12 Mess-/Kostenstelle 5 Mess-/Kostenstelle 13 Mess-/Kostenstelle 6 Mess-/Kostenstelle 14 Leistung: xxx kwh Mess-/Kostenstelle 7 Mess-/Kostenstelle 15 Öl: xxx m³/h Mess-/Kostenstelle 8 Mess-/Kostenstelle 16 Gas: xxx m³/h Datum Trend 1-4 Trend 5-8 Trend 9-12 Trend Berechnung en Einstellungen As one of the most important modules we offer you a coupling of your production to your management system with the interface to the ERP system. Thus an unlimited data connection and communication is possible that enables maximum transparency. You will be in the position to recognize the workload of your production, to activate possible unused potential and to increase productivity. are aligned and brought together. An energy optimization and efficiency increase is not or not sufficiently possible without this interface to the ERP system, which is already available with our module load management or our module plant information system. How does this work in practice? By using our operating devices you already have the possibility of establishing an interface to your ERP system. A definition of this interface is individually adjustable according to your demands and conditions. Additional energy can be saved by organizational planning if processes Input Energy meter Electric meter Gas meter etc. Status of the plant or machine Order from the ERP system Detection of faults Detection of good and bad parts Order from the ERP system + Interface ERP to the production Output The status of the order will be transmitted continuously to the ERP system Overall equipment effectiveness Production status messages Intelligent connecting of energy consumers Availability Performance Quality Display Documentation Logging

8 Foog & Beverage Automotive Building Technology Handling Technology Renewable Energy Water/ Sewage Environment Packaging VIPA worldwide in about 60 countries at home VIPA GmbH Ohmstr Herzogenaurach Germany Ph.: Fax: VIPA 03/2013 EK SIMATIC, STEP, SINEC, S7-300 and S7-400 are registered trademarks of Siemens AG