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Muvia Industrial

Energy use per line and per piece

Meters and power analysers read over Modbus TCP, joined with the pieces produced and the orders in the ERP: how much energy each line, each shift and each piece takes, with an alarm when consumption looks out of the ordinary.

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Illustrative scenario: it describes a typical case, not a customer project.

Diagram: power analysers and energy meters on Modbus TCP and the piece counters of a Siemens S7 PLC come in from the field; the ERP brings orders and items, an Excel file the shift calendar. Muvia produces the energy dashboard, kWh per piece, an alarm on abnormal consumption and the monthly PDF report.

The energy bill tells you how much you used, not where or for what.

The energy invoice arrives once a month, for the whole plant. Management accounting splits it by estimate, and the production manager cannot tell which line, which shift or which item weighs most.

The meters on the switchboard and the power analysers already measure everything, all the time. Put next to the pieces counted by the PLC and the orders in the ERP, they become consumption per line, per shift and per piece, updated every day.

Who it's for
Energy managers, production and plant managers, management accounting.

What you get

Consumption has an address
Every kWh is attributed to a line, a shift and an item, not to the plant as a whole.
Waste shows up straight away
Draw on a stopped line or an unusual shift triggers an alarm, without waiting for the bill.
The same figures as management accounting
Energy per piece starts from the same ERP orders the finance team works with.
A report that sends itself
The monthly PDF goes out on schedule with the same charts as the dashboard, with no spreadsheets to rebuild.

For the technical team

How it is built in Muvia

  1. 1

    Read meters and analysers

    On the edge node you configure the Modbus TCP driver with each analyser's active energy and power registers, and the S7 driver for the piece counters. The node reads them and sends them to the cloud, with a local buffer if the network drops.

  2. 2

    Compute consumption over the period

    The ready-made “Consumption over a period” analysis turns the cumulative counter into kWh per hour, per shift or per day, line by line.

  3. 3

    Bring consumption down to the piece

    A query joins each line's kWh with the pieces counted by the PLC and the orders copied from the ERP: energy per piece, per item and per order.

  4. 4

    Compare shifts and periods

    With the shift summary and period-over-period comparison you see how consumption changes across shifts, weeks and months, on the same dashboard that runs on the wall screen in the plant.

  5. 5

    Raise alarms and send the report

    A threshold with a deadband flags unusual draw, such as a line consuming while its machines are stopped. At month end a notebook becomes a PDF emailed to management.

SQL query

SELECT e.line,
       o.item,
       sum(e.energy_kwh * p.share)   AS kwh,
       sum(p.pieces)                 AS pieces,
       round(kwh / pieces, 3)        AS kwh_per_piece
FROM   hourly_energy AS e
JOIN  (SELECT line, hour, order_no, pieces,
              pieces / nullIf(sum(pieces) OVER (PARTITION BY line, hour), 0) AS share
       FROM   hourly_pieces) AS p ON p.line = e.line AND p.hour = e.hour
JOIN   erp_orders    AS o ON o.order_no = p.order_no
WHERE  e.hour >= toStartOfMonth(today())
GROUP  BY e.line, o.item
ORDER  BY kwh_per_piece DESC
kWh per piece, by line and item, for the current month: hourly consumption, counted pieces and ERP orders in one query. An hour shared by two orders splits its kWh by pieces.
The data it needs
  • Energy meters and power analysers read over Modbus TCP
  • Line piece counters from a Siemens S7 PLC
  • Orders and items from the ERP, copied from SQL Server
  • The shift calendar from an Excel file
Parts of Muvia used

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Tell us which machines you run. We'll tell you how to read them.

PLC brand, protocol, how the floor is connected: with those three answers, in a demo with one of our engineers, we show you how Muvia Industrial puts line data next to the rest of the business.

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