Integrate manufacturing data to achieve advanced energy analysis and energy management.
MainGATE/PPA for EMS (Energy Management System) is an energy management and analysis tool based on a manufacturing management and performance analysis package. As a Factory Energy Management System (FEMS), it integrates not only energy measurement data but also manufacturing data such as operational information of production equipment and product shipment volumes, enabling detailed energy analysis. Additionally, for Building Energy Management Systems (BEMS) in office buildings, it can be easily constructed using templates based on extensive experience. It analyzes energy consumption from various facilities such as heat sources, air conditioning, and lighting, achieving optimal energy management. By utilizing energy measurement technology from EMS (Energy Management System) and leveraging analytics, AI, and IoT, it enables advanced energy management through detailed analysis of energy data. *PPA: Process Performance Analysis
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basic information
■Benefits of Utilizing Energy Management and Analysis Tools - Improvement of Operational Efficiency of Energy Supply Equipment By enabling advanced analytical functions using AI technology, it allows for a detailed understanding of the operational status of energy supply equipment and the formulation of optimal operational plans. This helps to suppress unnecessary operation of equipment, reduce energy costs, and achieve stable energy supply. - Improvement of Production Efficiency of Production Equipment By monitoring the energy consumption of production equipment in real-time, it enables the detection of equipment anomalies. This helps prevent production stoppages due to equipment troubles and contributes to the stabilization of production plans. For example, by identifying and improving processes with high energy consumption, an increase in production efficiency can be expected. - Improvement of Yield of Manufactured Products By analyzing the relationship between energy consumption and product quality in the production process, optimal energy management that leads to improved yield can be achieved. For instance, by adjusting energy consumption in specific processes, it can reduce the defect rate of products and contribute to the stabilization of product quality.
Applications/Examples of results
■Examples of Optimal Energy Use and Cost Reduction Before implementation, there were challenges with gas turbine full operation, reverse flow occurrence, and steam and boiler fuel costs. Therefore, we enabled demand forecasting for electricity and steam, achieved optimal operation of the cogeneration system, reduced the amount of electricity received, and lowered fuel costs for exhaust gas boilers and auxiliary boilers. ■Examples of Data Visualization and Work Efficiency Improvement Across Multiple Factories This is a case of implementing a data visualization and analysis system for factories. The company needed to obtain real-time data from each factory to enhance management. By implementing the system, data collection and analysis from multiple factory locations were automated, information sharing through dashboards was promoted, and efficiency comparisons and variance analysis based on the same KPIs became possible. Work efficiency related to manufacturing management improved by 15%. ■Examples of Information Sharing and Decision Support Using Factory Data This is a case of implementing a visualization system using dashboards. The company faced challenges such as task dependency and lack of information sharing in production processes and quality management. To address these issues, a system was established to visualize various data, including equipment operation status, on dashboards, enabling information sharing and rapid decision-making based on data.
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MainGATE/PPA for EMS
Current Status and Challenges of DX (Digital Transformation) in Production Management in the Food Manufacturing Industry
Case Study: Reducing Energy Costs and Fuel Expenses through Demand Forecasting of Electricity and Steam
Case Study: Visualization and Analysis of Real-Time Data from Multiple Factory Sites
Case Study: Streamlining Manufacturing Management Operations through the Implementation of a Production Order Deployment and Performance Collection System
Case Study: Manufacturing Information Management System
Case Study: Energy Saving Analysis Support System
Current Status and Challenges of Manufacturing Industries Working on Energy Visualization for the Food and Chemical Industries
Current Status and Challenges of Decarbonization Efforts in the Food Manufacturing Industry 2025
Company information
Providing solutions for various plants and factories such as food, chemicals, oil and gas pipelines, paper and pulp, and cleaning facilities. Our measurement and control systems have over 40 years of history since the launch of the first distributed control system in 1975. Based on our track record, we propose systems and solutions to support the latest technologies, IoT utilization, and the development of smart factories. - Steam generation heat pumps / waste heat utilization / visualization of thermal energy - Clamp-on steam flow meters / flow meters / flow sensors / thermal balance analysis - Industrial furnaces / electric furnaces / high-frequency induction furnaces / IGBT power supplies - Gas analyzers / gas measurement devices / gas analysis sensors - Predictive maintenance / anomaly detection maintenance / preventive maintenance / maintenance and prevention systems / smart security - Smart factory - MES / DCS / SCADA / edge controllers - EMS / energy management systems / visualization of energy - Smart glasses / remote work support systems - Multivariate analysis / MSPC - Engineering tools
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