Smart Energy Management in Manufacturing Plants Using PLC and SCADA
Keywords:
Energy optimization, Industrial IoT, Manufacturing automation, PLC, ROI assessment, SCADA, Smart energy management, Statistical analysisAbstract
This research paper presents a comprehensive study on implementing smart energy management systems in manufacturing plants through the integration of programmable logic controllers (PLCs) and supervisory control and data acquisition (SCADA) systems. The study examines advanced methodologies for real-time energy monitoring, automated control strategies, and optimization techniques that hold significant potential for reducing energy consumption in industrial environments.
A comprehensive case study was conducted at a mid-sized automotive parts manufacturing facility over a 12-month implementation period. The research methodology employed statistical analysis of 8,760 hourly measurements across multiple performance parameters, utilizing paired t-tests with 95% confidence intervals and seasonal adjustment for HVAC loads. The integrated PLC-SCADA system incorporated Siemens S7-1500 controllers with WinCC SCADA infrastructure, featuring real-time energy meters with Modbus RTU communication and custom optimization algorithms developed in structured text programming.
Results demonstrate substantial improvements across all monitored metrics: 28% reduction in total energy consumption, 28% decrease in peak demand, 35.1% reduction in carbon footprint, and 24.1% improvement in equipment efficiency (p < 0.001 for all measurements). The implementation achieved superior performance compared to industry benchmarks, with energy savings exceeding typical ranges of 15–20%. Financial analysis reveals compelling returns with 37.1% ROI in Year 1, escalating to 542.3% over five years, while operational benefits include a 63% reduction in unplanned downtime and a 42% improvement in equipment utilization. The study provides a validated framework for scalable smart energy management deployment across manufacturing sectors, addressing critical needs for energy efficiency, cost reduction, and environmental sustainability in industrial operations.
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