Problem
A small-scale factory was experiencing continuously rising electricity costs, even though production levels remained relatively stable. The management team had limited visibility into how electricity was being consumed across machines, auxiliary equipment, and non-production hours.
In many cases, machines remained active during off-production hours, while systems such as compressors, lighting, and idle equipment continued consuming electricity without proper monitoring. Since the factory only reviewed monthly electricity bills, there was no clear way to identify where the energy waste was happening.
The key issues included:
- Lack of machine-level energy visibility
- Uncontrolled off-hour machine usage
- Auxiliary equipment consuming power unnecessarily
- No accurate method to allocate energy costs per production consignment
These inefficiencies resulted in higher electricity expenses and reduced operational control over energy usage.
Impact
Because the factory lacked real-time monitoring and energy analytics, management struggled to understand the actual drivers behind increasing electricity costs.
This led to several operational challenges:
- Higher electricity bills without clear explanations
- Difficulty identifying energy waste during non-production hours
- Poor visibility into auxiliary equipment energy consumption
- Inability to accurately calculate energy cost per production batch or consignment
Without actionable data, energy remained an uncontrolled overhead cost rather than a measurable operational parameter.
Challenge
The primary challenge was to provide clear and actionable visibility into energy consumption across factory operations without disrupting production.
The solution needed to:
- Monitor machine-level electricity consumption
- Identify off-hour energy usage
- Track auxiliary loads and hidden energy waste
- Provide a centralized platform for energy monitoring and analysis
- Enable management to allocate energy costs accurately per consignment
At the same time, the system had to remain simple, scalable, and suitable for small industrial environments.
Solution
Daitan Solutions deployed a smart energy monitoring solution designed to provide real-time visibility into factory energy consumption.
The implementation included:
Smart Energy Monitoring
Energy analyzers and smart meters were installed to collect real-time electricity data from critical machines and factory zones.
Machine-Level Energy Tracking
The system enabled factory management to monitor energy consumption per machine, helping identify inefficient equipment and unusual usage patterns.
Off-Hour Consumption Monitoring
Energy usage during non-production hours was tracked to identify machines and auxiliary systems consuming electricity unnecessarily.
Centralized Energy Dashboard
All energy data was integrated into a centralized monitoring platform, allowing managers to analyze consumption trends and identify opportunities for energy optimization.
Result
After implementing the solution, the factory gained clear visibility into how electricity was being consumed across its operations.
Key outcomes included:
- Reduced electricity bills by identifying off-hour energy waste
- Improved operational discipline in machine usage
- Visibility into auxiliary load consumption
- Accurate energy cost allocation per production consignment
- Better decision-making through real-time energy insights
With the help of Daitan Solutions, the factory transformed energy from an unmonitored overhead cost into a measurable and manageable operational resource.
