How to Manage the Energy Consumption

What's the 42Q’s Energy Consumption

  42Q offers a powerful Energy Consumption Functions system, which consists of three integral modules: CMMS, OEE, and IIoT. With this system, users can efficiently track and monitor energy consumption, including gas, water, and electricity. This How-To guide will walk you through the process of setting up and utilizing the Energy Consumption Functions effectively.  

Main Features

The main features involved:

1. Plant machine (asset id or tag id) to send their energy sensor data to 42Q MES via a new MES-API. - MES-API
2. Associate the data to OEE events and track the history status for assets. - CMMS/OEE
3. Check OEE reports for energy consumption - OEE reports under MESWeb
4. Show time-serialized energy for 24 Hours at IIoT dashboard. - IIoT Dashboard
5. Alert to users for abnormal consumption. -IIoT Alert

 

How to Manage Energy Consumption

 

 Create Asset ID/Tag ID for Energy Tracking

    

  There are two scenarios for the plants to send the energy data to the 42Q system: By Asset ID or By Tag ID.  

• By Asset ID

For this scenario, the plant sends the energy data by Asset ID, then the users just need to create an Asset ID , no need to do tag mapping, but the limitation indicates only one energy type (power or gas or water) can be monitored.   

• By Tag ID 

  For this scenario, the plant sends the energy data by Tag ID, then the users not only need to create an Asset ID, but also need to add one or more newTag ID at thetag mapping function to mapping the asset to the tag. Each tag can be selected as one tag type, more tags are attached on the asset ID.     

 Send the Energy Consumption Data

     The users need to Set up the MES-API. Connect Plant Machines to MES-API: Allow plant machines (assets) to send their energy sensor data to the 42Q MES system via a newly configured MES-API.    Create Asset Mapping for Asset ID & Location to get the finished qty with energy consumption data from the MES101.
Link Energy Consumption Data to OEE Events: Associate the energy consumption data collected from plant machines with the corresponding OEE events. This association enables you to correlate energy usage with production activities.   Set the SOMS Target and s report the asset events with energy consumption data at the OEE Data Collection.  

Energy consumption Report 

  There are three options where to view the energy consumption data:   Monitor Asset Status History , Access OEE Reports for Energy Consumption and Utilize the IIoT Dashboard.

Monitor Asset Status History: Track the historical status of assets to gain insights into energy consumption trends over time.

 

Access OEE Reports for Energy Consumption: Check the three OEE reports dedicated to energy consumption available under MESWeb. These reports offer in-depth insights into your energy usage patterns.

 

 Utilize the IIoT Dashboard: View Time-Serialized Energy Data: Leverage the IIoT Dashboard to visualize time-serialized energy data for a 24-hour period. This feature allows you to identify peak energy consumption times and optimize energy usage accordingly.

 

Abnormal Consumption Alerts

Set Up Abnormal Consumption Alerts: Configure IIoT alerts to notify users of any abnormal energy consumption patterns. These alerts will help you proactively address unexpected spikes or drops in energy usage. Then the users need to configure IIoT Alerts.   Create Email Topic and Rules at the IIoT Configuration function. 

How to Configure (Detail steps)

  The following are the configuration steps, please configure according to your own situation, you may need all the steps, or can skip a few steps.  

Step 1: Create Asset ID for Energy Tracking

 

Navigate to Shop Floor Control > Configuration > CMMS Asset > Asset.

Under the Asset sub-module, click on "ADD ASSET" from the top right menu. The "add asset" window will appear.

Enter all the needed information of the asset, then select SAVE to add a new asset id to track the energy.

 

Note: The users can go to the CMMS-Asset for more details to add new assets.   Before the users set up an Asset ID,  the Asset Type/location/line/group should be kind of preconditions to using the basic CMMS functions.  

CMMS asset type/location/line/group

  If the user has already set that information, this step can be ignored.  

Navigate to Shop Floor Control  > Configuration > CMMS-Admin

Select Group to configure groups.

Navigate to Shop Floor Control  > Configuration > CMMS-Asset

Select Production Line/Location/Asset Type to configure the information.

  Note: The users can go to the CMMS- Admin and CMMS-Asset modules to configure the Asset Type/Location/Production Line/Group information.

Create Tag ID

The create Tag ID steps just for the scenario that the plants send the energy data to the 42Q system by Tag ID.

If by Asset ID, this step can be ignored.   Create Tag ID if the users want to send the sensor data by sensor rather than by machine level, create tag id for one asset if the users want to specify tag id.  

Navigate to Shop Floor Control > Configuration > OEE Configuration > Tag Mapping.

 

2. Under the tag mapping sub-module, select ADD TAG MAPPING from the top right menu to add a tag ID.

 

 

3. Enter all the needed information of the asset, then select SAVE to add a new tag id.

  Note: The users can go to the Tag Mapping for more details to add a tag ID.  

Step 2: Asset Mapping between Asset ID and Location to get the finished qty

  Add a mapping between the Asset ID and the Location. Here the location means SFDC(Shop Floor control MES101) location for scanning. All the scanning activity is expected to be achieved at PWB or scanning system. Otherwise there will be no finished qty retrieved from MES101.

Navigate to Shop Floor Control  > Configuration > CMMS-Asset > Asset Mapping.

Select Add to add a new mapping between the shop floor location and asset.

Enter all the needed information, then select Save to add a new mapping.

  Note: The users can go to the CMMS- Asset to configure the Asset Mapping.

Step 3: (optional) SOMS Target 

  The users can check the OEE reports with the target qty, the OEE (Availability/Performance/Quality) data can be shown at the reports.

If the users want to check the OEE reports, they should set the target quantity at the Target Maintenance module.  

Navigate to Shop Floor Control  > Configuration > Target Maintenance.

Select Add (+ in green) to add a new SOMS Target with the target qty.

  Note: The users can go to the Target Maintenance for more details to configure the Target qty.  

Step 4: Send energy data by MES-API. 

The MES-API will send the meter reading( energy consumption information) data every minute automatically to the 42Q CMMS/OEE. Please contact the GBS team for the API setup steps.    Here is an example of setting test data manually.

payload example: (notes: timestamp please use milliseconds format)   />

{   "send_to_cmms": true,   "send_to_iiot": true,   "data_acquisition_ts": 1689581835000,   "measurements": [     {       "id": "ACENERGYW",       "agent_id": "",       "tag_type": "water",       "value": "95.5",       "uom": "t",       "root_cause": "",       "quality": true,       "timestamp": 1689581835000     }   ] }

     

Step 5 : create OEE events 

If the users want to automatically run the plant’s machine by shift ,but no shift has been set up, they should set up the shift first.  

Navigate to Shop Floor Control > Configuration > OEE Configuration > Shift.

Under the Shift sub-module, select Add from the top right menu. The Add Shift window appears.

Enter all the needed information of the shift, then select SAVE to add a new shift

Note: The users can go to the OEE Shift for more details to add a new shift.

 

Navigate to Production >  OEE Data Collection.

Under the sub-module, select Add (+) from the top right menu. The Report Asset Event window appears.

   

 

 

3. Enter all the needed information, then select Save to report asset events.

  Note: The users can go to the OEE Data Collection for more details to report OEE asset events.    

Step 6: Asset view to history status for OEE events with energy data 

The users can view the energy data at the CMMS Asset view module after the energy consumption data entered into the CMMS system by API or by OEE Data collection.  

Navigate to Shop Floor Control  > Configuration > CMMS-Asset > Asset View.

Select the Asset, then select View from the top right menu. 

Select History Status > Asset Status History tab.

   

 

4. The Energy Consumption information show.

Step 7: OEE reports to check energy consumption

The users can view the OEE reports with the energy consumption information.

There are three reports:   

Historical energy consumption

Energy consumption by shop order

Energy consumption by product

 

Navigate to Reporting > MESWeb > OEE Report.

Select the Historical energy consumption/Energy consumption by shop order/Energy consumption by product.

The reports will display.

  Figure 10:  OEE Reports with Energy Consumption   https://lh5.googleusercontent.com/GZg0Eo5Nzw7Qbr7kE3OkKCOdxzabrq1CrWczITpr34jLiin4Th9FVS6s6nf-r_7VJw5CmK6gz_Vl3QUHxsMqs_I51YexHd4A-PYTIA1FVZBPXMBZgA4mva3lTDlbM3Pr0WD1OJPjnBDVa8aWgeYsVPU

Note: The users can go to the MESWeb - OEE Reports for more details.

Step 8: Create a widget to display a 24-hour time series energy on the IIoT dashboard.

IIoT dashboard to show hourly consumption data over the past 24 Hours with upper/lower limit.

Navigate to Shop Floor Control > Configuration > IIoT Dashboard > Widgets.

Select Add ICON( +) to add a new widget to show the energy consumption.

At the Add Widget sub-page, go to the THINGS tab.

Select the Thing ID, then select SAVE.

Step 9: Create a topic and subscribe to it.

The users can set the Email Alert for abnormal consumption.

First to create a topic and subscribe to Email, then set the rules for the Email Alert action.   

Navigate to  Shop Floor Control > Configuration > IIoT Configuration > Notification Setup.

Select CREATE SNS TOPIC.

Edit the Topic created at step2.

At the Subscribe list page, select SUBSCRIBE TO SNS TOPIC.

Add a subscribe Email.

 

Step 10: Create a new rule to trigger an alarm action when abnormal data is detected.

Create a new rule for the Email Alert Topic. The users can set the Notification Interval, Max Alert Times, Control Values, and other rule options.  

Navigate to Shop Floor Control > Configuration > IIoT Configuration > Rules.

Select CREATE RULE.

Select Group and Things, Define Bound Independent, Create Rule Parameters ,and publish rules.

Select Save.