CASE STUDY

Manufacturing Operations Analytics Solutions Reduced Production Energy Consumption for Major Manufacturers?

Aug 26, 2022

Highlights of the Case Study: 

Particulars Description 
Client A leading metal manufacturer in India with production plants in the UK wanted to transition toward an energy-efficient production process. 
Business Challenge The client partnered with Quantzig to leverage its advanced manufacturing analytics solutions to rejuvenate the entire production process, making it energy-efficient with a good ROI.  
Impact Quantzig’s manufacturing operations analytics helped the client transition to a greener manufacturing plant within the same installed capacity, achieve its energy goals, and improve profitability. 

Game-Changing Solutions for Manufacturers 

Why do organizations analyze manufacturing? Carbon emissions continue to rise, making the Earth 1.1 degrees Celsius warmer than it used to be in the late 1800s. These emissions must be cut down by 46 percent to reach the net zero emission target by 2050. The energy sector generates around three-fourths of carbon emissions today and is, therefore, the starting point to initiate a reduction in global carbon footprint.

  

Quantzig estimates that energy consumption during production makes up about 30 percent of the total energy consumption and will rise by 1.2 percent annually. The paper, metal, and chemical industries account for more than 60 percent of the energy consumed in the manufacturing industry. Therefore, reducing the energy consumption in these industries would drive us closer to our goal. Quantzig aims to help businesses achieve high energy efficiency using advanced manufacturing analytics solutions.  

The Challenges of the Manufacturing Client 

A leading metal manufacturer in India that has production plants in the UK had to shut down its operations due to a lack of financial aid and high costs involved in transitioning toward an energy-efficient production process. The client partnered with Quantzig to leverage its advanced manufacturing analytics solutions and data intelligence to rejuvenate the entire production process, making it energy efficient with a good ROI. The client was facing the following energy challenges with the current manufacturing setup:  

  • Strict regulations pushed the client for a quicker transition toward an energy-efficient process  
  • Lack of financial aid from the government as transition requires heavy investment  
  • Difficulty in finding alternate solutions to low carbon emission  
  • Massive investment in blast furnaces that require thermal energy to provide the right temperature for reaction rates  
  • Substantial yield losses due to equipment failure, reduced speed, idling, and production defects increase the carbon footprint and increase the amount of energy consumed.

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Manufacturing Operations Analytics Solutions 

Quantzig’s process intensification (PI) techniques backed by data-driven solutions suggested non-thermal, low-carbon alternatives to traditional, high-temperature production technologies enabling more efficient manufacturing and recovery of metallic and non-metallic materials. Such technologies enabled water-based, selective recovery of critical components from low-grade minerals, extracting valuable materials from outdated electronic pipelines and waste, and low-temperature, high-efficiency chemical processes.  

We deployed remanufacturing and additive manufacturing techniques over traditional subtractive processes such as moulding and forming, reducing waste and carbon intensity of the metal produced. Further, to avoid energy consumption due to yield losses, we implemented data-driven upkeep strategies to check overall equipment effectiveness to minimize the energy wasted on production rejects and defects.  

Impact Analysis of Quantzig’s Manufacturing Operations Analytics Solutions  

Quantzig’s team was able to help the client by leveraging manufacturing operations analytics, which enabled the transition to a greener manufacturing plant within the same installed capacity. The client was thus able to meet the stipulated energy goals and achieve a good ROI within a year.  Some of the benefits of our successful partnership are listed below:  

  • 70 percent reduction in energy demand, in tune with a 30 percent cut in the energy bill  
  • Reduced carbon footprint using renewable energy alternatives such as hydropower during the production process   
  • This partnership enabled the client to use a recyclable option with low carbon emissions  

Key Outcomes of Manufacturing Operations Analytics:

The client wanted to leverage Quantzig’s industry expertise backed by operational analytics solutions to restructure its manufacturing processes cost-effectively. Our intervention helped the client reduce its carbon footprint by making its manufacturing processes more efficient and exploring alternative energy sources such as hydropower. Such initiatives need to be implemented by all manufacturers and will be crucial in achieving the goal of net zero emission by 2050.  

Manufacturing units must rely on scientific data-backed solutions to optimize their manufacturing plants and explore all the possible ways in which they can opt for greener solutions to help avert the irreversible effects of climate change.  

A Broad Perspective on the role of Operations Analytics Solutions in the Manufacturing Sector: 

Emerging and advanced manufacturing technologies can reduce process time, parts usage, and production rejects and defects, thereby reducing the energy consumed in the manufacturing value chain. The same goes for technologies enabling the producers of materials and components that enhance recycling and recyclability. These advances will assist in improving sustainability, reducing industrial waste, and decreasing the energy consumption in the manufacturing process.  

Quantzig’s manufacturing analytics solutions can leverage data-driven maintenance, process intensification, and predictive analytics to reduce the thermal energy requirement and annual energy bill. These insights, data backup, and dashboards enable businesses to establish energy-efficient production processes quickly.  

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Key Takeaways 

Quantzig’s manufacturing analytics solutions enabled the following benefits in the energy sector: 

  • 70% reduction in energy demand 
  • 30% cut in energy bills  
  • Introduction of renewable energy solutions 
  • Optimization of the manufacturing process to reduce rejects 
  • Reuse and recycling in operations to reduce carbon footprint 

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Related Articles: 

Machine Learning Solutions Optimized Manufacturing Line for a Major US-Listed Copper Manufacturer 

How did a Leading Aluminum Manufacturer Improved Its Manufacturing Process with Demand Forecasting Analytics? 

How Digital Twin Technology Helped Manufacturing Client to Predict Equipment Anomalies? 

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