Process Metals (Energy)
Process Metals — Smarter Energy, Lower Rework
Track consumption per unit, shift demand out of peak windows, and align maintenance with production signals to cut rework.
Process Metals
Energy monitoring and load shifting reduced peaks; visibility aligned maintenance to cut rework.
kWh/unit: −14%Peak Load: −11%Rework: −9%
What you’ll get
- Load-shift recipes
- Peak window alerts
- Cost impact model
Challenge
A metals processor faced two major challenges: energy costs spiking due to peak demand and frequent rework caused by unaligned maintenance and process instability.
Solution
- Deployed energy monitoring dashboards to track consumption per unit.
- Introduced load-shift scheduling to smooth peaks and lower energy costs.
- Aligned maintenance schedules with production data to reduce variability.
Results
kWh/unit: −14%Peak load: −11%Rework: −9%
Toolkit Provided
Load-shift recipes
Move demand out of peak windows without losing output.
Peak window alerts
Act before penalties hit; avoid demand charges.
Cost impact model
Show energy and rework savings in real time.