Smart Metering Solution for an automobile part manufacturer

Tech Stack

IoT
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The Client

The Client

The client is into manufacturing and sales of gaskets for automobiles and packing for general industries. It manufactures parts and accessories for motor vehicles and their engines [brakes, gear boxes, axles, road wheels, suspension shock absorbers, radiators, silencers, exhaust pipes, steering wheels, steering columns and steering boxes and other parts and accessories.]

The Objective

Their manufacturing plant is deployed with some 70 machines that help in the process. The client had energy meters installed at all the individual devices, and the energy readings were noted manually. This was a time taking and cumbersome process. The client required automated monitoring of energy at the deployment to save on costs and energy, while reducing dependency on humans.

The Objective

The Solution

Solution

  • Industrial IoT was used, with 6 nos. three phase smart meters installed at client site, and a hierarchy created.
  • The main meter is in the utility area, while the other meters are installed on the individual machines.
  • The main meter displays the total reading of the five meters, while the consumption of the five individual submeters should match the reading on the main meter.
  • Due to variance, the meter readings sometimes do not match, which enables the client to identify the faulty area.
  • The power factor of the devices in the plant is monitored through smart meters, which enables the identification of the machine low in efficiency and high on energy consumption.
  • Maintenance of the machine increases the power factor and decreases its power consumption.
  • Everyday the reports are sent to the client on the various parameters.

The Outcome

Outcome
  • IoT technology enabled reduction in energy consumption of about 15% to 18% in the utility area.
  • Savings on cost of production and energy.
  • 20% ROI
  • Less human dependency.

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