A Framework for Quantifying Energy and Productivity Benefits of Smart Manufacturing Technologies

Enhancing operational performance and productivity benefits in breweries through smart manufacturing technologies

“…Under a reasonable assumption of $350/HL for the variable O&M cost, Figure 4 shows that if the CPS energy use is less than about 5.7 GWh/year (intersection of the energy price plane with the CCE surface at VOM = $350/HL), the CCE for this SM intervention would be favorable and the SM intervention would be cost-effective from an energy standpoint. This CPS energy budget of 5.7 GWh is three orders of magnitude higher than the roughly 5 MWh/ year energy use associated with cloud computing and the content service calculated based on power consumption rates described by Baliga et al 31 Additional details supporting these calculations can be found in Supekar et al 24 3.2 | Case study 2: replacement of traditional manual lauter tun by a fully automated and networked mash filtration system Full Sail Brewery, like the vast majority of craft brewers, uses a lauter tun, a manual brewing vessel, to filter the slushy mash of water and crushed grain that contains the sugars fermented to produce beer. The lauter tun system requires continuous, manual data testing and reporting.…”

“…To facilitate decision-making regarding whether SM interventions create significant value and improve energy F I G U R E 1 Overview of the brewing process and its material flows. SM and IoT strategies with potential applications in the brewing process are shown in blue boxes productivity in breweries, we used an analysis framework proposed by Supekar et al 24 The framework proposes that key performance indicators (KPIs) should define the specifications of the cyber-physical system (CPS) and define the analysis system boundaries (Figure 2A). The CPS is a physically aware engineered system that has tightly collaborating "cyber" components (those that can compute, communicate, and control) with the physical world (eg, boiler system, chiller system, process equipment), providing a wide range of control and optimization strategies.…”

“…Note that the energy use term in Equation (1) includes the energy use of the CPSs within the factory and any upstream/downstream energy uses resulting from the CPS, such as large data servers. Additional details of the CCE metric and the systematic analysis framework can be found in a paper by Supekar et al 24 It should be noted that the CCE metric may also take into account additional hardware, software, and human resources costs associated with improving cybersecurity. It is apparent that the additional cybersecurity costs would affect the cost of conserved energy.…”

“…A detailed version of this case study is provided in Supekar et al 24 (the other work published by the primary authors). Herein, we provide a brief overview and summary key findings of the energy productivity analysis of F I G U R E 2 A, Key performance indicators (KPIs) determine the target metrics to be measured and define the system boundaries within which to quantify the energy productivity impacts of a smart intervention.…”

“…B, The cost-effectiveness of various SM interventions or strategies aimed at improving specified KPIs is measured using the cost of conserved energy (CCE) metric. Figure obtained from Supekar et al 24 this particular SM intervention. Deschutes Brewery (Bend, Oregon) produces different types of beers to maintain customer interest.…”