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A methodology for determining auxiliary and value-added electricity in manufacturing machines

A methodology was developed that accurately and flexibly determines the auxiliary (AU) and value-added electricity in manufacturing operations. A tool was developed for production engineers which allows for the verification of machine efficiency in relation to their energy consumption. Historical production and electricity consumption data were collected for a period of three months from four different machines in a value stream at a manufacturing facility. The data were examined using a methodology based on statistical analysis of the historical data collected and were verified using heuristic machines profiles. Results showed AU electricity consumption varied between 10 and 26% per machine. When weekend data (non-productive periods) were excluded from calculations, AU electricity consumption reduced. Past work focuses on optimising single machine, and the quantification of wasted electricity is not always clear. This research work can be applied to one or more machines, and to single or multiple products passing through the same machine. It places particular attention to AU electricity since potential energy and cost reduction of up to 20% could be achieved. Hence, this work can aid in developing key performance indicators to measure energy usage in manufacturing operations, particularly focused towards reducing AU electricity consumption.