IoTellect

Steirer Präzisionstechnik GmbH, a precision metalworking shop, required a solution to gain real-time visibility into their energy consumption per production line to control their spiking electricity costs. Additionally, they needed a mechanism to prevent equipment from running unnecessarily outside production hours, thus utilizing power unproductively. Enters IoTellect, selected based on high ratings, budget-friendly pricing, and value for cost. IoTellect successfully delivered the project within approximately five weeks featuring the integration of a real-time energy dashboard that displayed consumption statistics and alert configuration for equipment operation outside production hours.

IoTellect implemented a robust monitoring system that linked 12 power meters and 4 PLCs across CNC milling, turning, grinding, and the compressor room. This integration included a combination of older Modbus meters and more recent OPC-UA devices, without the need for hardware replacement. The installed system provided operators and shift leads a glance at power usage and also flagged any equipment activity during non-production hours. The dashboard was user-friendly, eliminating the need for an IT middleman for daily checks.

This energy monitoring system swiftly began to show results. It detected an anomaly where a compressor was running at full load during weekends when the plant was empty. By rectifying this and making adjustments to the schedule, Steirer Präzisionstechnik GmbH managed to reduce their monthly energy bill by around fifteen percent. This significant reduction led to the system paying for itself within a quarter, validating the effectiveness and efficiency of the IoTellect solution. The main accomplishment was not a report or a document but the tangible change in the company's energy usage and cost management.