Smart management of factory energy conservation and carbon reduction: Amazing benefits accumulated from daily details
In the manufacturing industry, can we start from every small detail, continuously improve the process and achieve the goal of energy conservation and carbon reduction?
The answer is yes! Energy conservation and carbon reduction do not necessarily require large-scale technological transformation. Sometimes fine-tuning in daily operations can also bring significant benefits. Below, we share some of the factories’ specific practices in energy conservation and carbon reduction.

 

1. Always control process energy consumption: full-field power monitoring system
In modern factories, installing a 24-hour power monitoring system is a necessary means to improve energy management. By monitoring the power consumption of each device in real time, factories can quickly identify high energy consumption points and make further adjustments.

As shown in the picture, the power counter clearly displays the power consumption index of each zone. It not only helps managers understand the overall power usage, but also tracks the energy consumption peaks of specific processes. For example, if the energy consumption of a device suddenly spikes, potential problems can be immediately identified to avoid energy waste.

This type of monitoring system makes factories more transparent and intelligent in their energy use. At the same time, monitoring data can also be used to develop medium- and long-term energy-saving strategies, such as adjusting the way machines operate or selecting more efficient equipment.

 

2. Comprehensive carbon emissions measurement: Accountability for every part and consumable
In addition to focusing on electricity consumption, the factory is taking further steps to track the carbon footprints of various materials, such as bearings, gears, seals, and other components. These efforts include material selection and design, manufacturing processes, and integrated calculations of resource inputs like labor, water, oil, and cutting tools.

Through this system, managers can clearly understand the carbon emissions of each process:

Which processes are high carbon footprint links?
Which consumables can be replaced or effectively reduced?
How to balance carbon emissions and actual benefits?
These core data not only provide a reference for green manufacturing, but also help factories maintain production efficiency while reducing carbon footprint. In addition, when implementing carbon emissions measurement, it can also be further linked to employees' environmental awareness and skills training, so that energy conservation and carbon reduction can be truly integrated into daily management.

 

3. Smart process and meticulous management: everyone participates, everyone becomes stronger
The success of energy conservation and carbon reduction depends not only on technical means, but also on the lean management and silent dedication of every factory employee. In actual operations, factories are constantly seeking improvements in their working methods. For example, some highly repetitive production processes will bring about a fatigue period. At this time, if the standby power consumption of the power equipment can be reasonably reduced, or a more comfortable working method can be adopted, it will not only improve employee efficiency but also reduce unnecessary energy losses.
Timely adjustments to component design can also reduce material waste.

 


Full-field power monitoring system

 


Drying adopts natural ventilation and circulating hanging operation to reduce the power consumption of the oven

 


Finished products are placed vertically to reduce storage space

 


The material rack is equipped with wheels to reduce manpower time

 


Motor assembly project

 


OEM components are waiting to be installed

 

Smart daily life for energy conservation and carbon reduction in factories: the perfect combination of data visualization and process optimization
In the field of energy conservation and carbon reduction in contemporary smart factories, the intelligent integration of data monitoring systems and equipment processes has become an important pioneering force. Through detailed energy consumption monitoring and process improvement, the factory not only improves energy efficiency but also effectively reduces carbon emissions. The following are specific practices on power monitoring and process improvement.

 

1. Single process power monitoring platform: data-driven energy-saving leadership
As shown in the figure above, the factory installed a single process power monitoring platform to present the energy consumption data of all processes in a visual way:

Multi-dimensional monitoring of energy consumption indicators: The platform displays the specific power consumption data in various process operations. For example, hourly electricity consumption, energy consumption trends, and carbon emission ratios.
Real-time tracking and analysis: Energy consumption data is no longer just a single number, but a chart showing detailed information on high-energy consumption links, helping management quickly identify areas for improvement.
Support decision optimization: By combining energy consumption data and process efficiency, factories can set more accurate energy-saving targets. For example, for certain high-carbon emission links, shorten the operating time or adjust equipment performance.
This monitoring platform not only improves management efficiency, but also allows every employee to understand the energy usage in their own operations, motivating everyone to work together to reduce energy waste.

 

2. Process Optimization: Case Study of Energy-Saving Design for Shortening Worm Shaft Machining Process
How to shorten processing time and reduce energy consumption in the lean production process is one of the important challenges for factories to save energy and reduce carbon. Taking the worm shaft process as an example, the factory successfully achieved significant energy and time savings through process consolidation:

Process Integration: As shown in the flowchart, the factory condensed processes that originally required repeated movement between different equipment (such as thread rolling, sharp corner chamfering, keyway milling, polygon milling, etc.) into a single machine operation.
Consolidating machining processes and centralized machining methods make the manufacturing process of each part smoother, reducing transportation and waiting time for repeated loading and unloading, converting equipment accuracy error ranges, and improving processing efficiency and workpiece yield rate.
Reduce Carbon Emissions: By reducing the repeated operation between equipment, the factory effectively reduced energy consumption. According to actual measurements, the carbon emissions per unit process were reduced by 5 times, significantly improving the carbon reduction benefits.
In addition, intelligent single-machine operation also improved production efficiency and reduced the operational pressure on employees between multiple process points, making carbon reduction efforts more sustainable!

Data visualization + process optimization = a new paradigm for the green revolution
From power monitoring platforms to operational innovations in process integration, these methods demonstrate how smart factories can effectively maximize energy efficiency through data management and process improvement. At the same time, the concept of energy conservation and carbon reduction will be deeply integrated into every production link to create a more environmentally friendly and efficient green manufacturing future.

These innovative measures not only helped the factory achieve its carbon reduction goals, but also set an advanced example in the industry. In the future, we expect more factories to move towards a new era of green production through intelligent management and technology integration!

 


Process Carbon Footprint Data Collection and Presentation

 


Single process power monitoring platform