1Inferred Energy Approach
Model Production
Production Flows
Energy Flows
Build Inferred Energy Models
at Equipment Level

Drive out wasted energy inmanufacturing facilities throughthe development of software
technology to detect unknown or
unexpected energy consumption
across the facility without the use ofexpensive energy meters.
Incorporate Production Log, Predict
Consumption by Production Run

Rollup by SKU, Identify Outliers

Provide User Friendly Analytics toSupport Root Cause Analysis

Lessons Learned – Murfreesboro Facility (Yoplait)
Background: Yoplait in Murfreesboro is a well instrumented line with multiple levels of metering that canprovide energy usage by production line.
• Single model can be used to concurrently model product/material and energy flows• Clarity needed on roll up of energy consumption into usable groups– Production runs
– Weekly energy consumption summaries (roll-ups) by SKU, line, and site
– Normalize and compare consumption across runs, runtime, product• Highlight consumption by production line to be usable for the production team– Simplifies energy consumption and still yields actionable results– Big ticket items live in the “back of the house” infrastructure– Specific production lines/SKUs vs. “optimize chiller plant” are very different scopes of work
• Usability is key– Dedicated dashboards based on clear user stories– Visibility by shift and changeovers

Lessons Learned – Chanhassen Facility
Background: Chanhassen produces baked goods which has over a dozen production lines that aresporadically used. The facility has limited instrumentation and metering that supports all lines.
• Significant value can still be achieved even without significant instrumentation– Energy consumption patterns can be discerned and acted upon
– Change overs can result in wasted energy consumption during idle periods– Excessive demand charges present opportunity for improvements– Shift changes are logical points where action can be taken• Understand the large infrastructure energy consumers– Backroom compressors and ammonium boosters drive consumption• Production log is critical to define production events– Manual entry needs to be confirmed where possible with instrumentation– Validation of production log times can be achieved by mapping runtime states and breaker settings

Outcomes – Murfreesboro• Contextualizing energy data with SKU runs completelychanges the discussion with production team
- Energy as an ‘ingredient’ in the recipe- Strikes the ‘sweet spot’ where action can betaken• Running underutilized lines can accumulate excessive
cost by “overconsuming” energy• Some SKU’s require more energy than others;
opportunity to align energy intensive products withhigher efficiency lines• Energy Utilization Efficiency (EUE) is a useful metric toapply to a plant/individual production lines- Provides a normalized way to compare
operations

Outcomes – Chanhassen•

Changeovers often result in wasted energy
consumption during periods when no product wasbeing produced•

Energy consumption visibility can enable a tighter
set-up schedule for a new production run•

Ammonia equipment maintained much higher-thanexpected energy consumption during periods with
manufacturing equipment off•

Changeovers are optimal point to take appropriate
action•Could enable peak shaving and time shifting to
improve consumption efficiency•

Excessive demand charges present opportunity forimprovements

Connected Worker Platform – Expectations• Technical Experience – How does the system support front line workers?
• Technician's visibility to information• Technician completes a checklist (like CIL – Clean Inspect & Lubricate, Centerline etc.)• Technician's access to help (ex. equipment failure)• Operations Leader Experience. How does system support management of work and resources?
• Creation and scheduling of tasks/ procedures• Staffing and monitoring execution of work
• Skill/ team development• Transitioning into the new system. What would have to do to implement this system?
• Migration of existing instructions/ procedures into the system• Ability to inventory what is in system and where there may be gaps
• Ability of system to be integrated with existing systems