John Cosgrove Research Director – ACORN Research Centre Lead PI – TEMPO LIT

1. John CosgroveResearch Director – ACORN Research Centre Lead PI – TEMPOLIT

2. ACORN Research Centre • Applied Research, Industry Driven. • Focused on the Engineering of Sustainable Solutions for Industrial, Commercial and Utility Applications. • Key themes • Multi-disciplinary Group, Science, IT & Engineering, Enterprise Ireland Funded. • 24 Staff and Researchers.

3. Background EU Roadmap - Factories of the Future beyond 2013, DG INFSO, December 2010. IERC Initial Needs Assessment - Real-time Factory Optimisation – Smart Energy Networks, International Energy Research Centre, June 2011. TEMPO - Total Energy Management for Production Operations, Enterprise Ireland Technology Centre Collaborative Project, Start June 2012. • €1.7 m Collaborative Project, LIT, UU and Industry Stakeholders (I2E2 & IERC) • Collaborating Industrial Sites include, Johnson & Johnson (DePuy & Vistakon), Analog Devices, EMC, GSK & Carbery. • Pilot Site in DePuy, Cork, Embedded Researcher.

4. TEMPO Focused on establishing effective methods of monitoring total energy consumption during production in order to help companies to understanding where any excess energy is being used and to reduce overall energy costs. Functional Specification • TEMPO aims to deliver an internal software tool that will effectively track energy in production operations in order to accurately allocate usage to specific value streams. • Based on a structured analysis of the process flow and definition of hierarchical KPIs the system will provide visualisation of energy usage, optimisation opportunities and decision support. • Through a standardised approach, the system will be flexible and applicable to different manufacturing sectors.

5. SteeringGroup TEMPO • Stage 1 • 17 Researchers engaged in TEMPO, (7WTE), 4 linked postgrads. • Good Interaction with Industry Stakeholders, I2E2, DePuy, & IERC. Further interaction planned with GM (US). • Detailed Industry Surveys completed • Analysis of prior research on Energy in production and Energy KPIs completed. • Initial Energy Models and Optimisation techniques developed. ACORN, LIT PI: J.Cosgrove ISRC, UU PI: Prof. M.McGinnity TEMPO 2 x Staff 3 xResearchers 3 x Staff 3 x Researchers IndustryStakeholders

6. Stages

7. TEMPO Structure Stakeholder Engagement Smart Energy Network Industrial Pilot Energy Modelling Analytics & Visualisation Tools Dissemination& Commercialisation

8. Industrial Case Studies Detailed analysis: 5 Companies 7,000 employees 358 GWhr €28m Energy Spend (2010) Stakeholder Engagement

9. Refined Energy Model 57% Direct Energy 43% Indirect Energy Stakeholder Engagement

10. Product based Energy Model Ongoing Development Standardised Methodology of Assigning and Codifying Specific Energy Consumption Standardised Semantic Representation of Energy Performance Metrics

11. Key Challenges • Gaps in IT / ICT Infrastructure on the production floor • Energy cost allocated to business units in different ways • Challenging IRR approaches for energy efficiency (24 Months) • Decision / Priority Systems vary greatly • Initiatives needed on Operator Awareness of Energy as a cost • Significant reduction in GHG Emissions needs Local/Renewable Generation Options • Opportunities • To leverage existing Automation / SCADA as virtual meters for energy consumption • To leverage ISO50001 to give structured visibility of the system • Interval Based Utility Charges being rolled out • Strong view that Carbon Footprint will become a significant metric in the short term • Strong Corporate Drive for GHG Emission and Water Usage tracking and reduction

12. Optimisation • Specification • Methodology (+/- 10%) for allocating Direct Costs and apportioning Indirect Costs to Specific Value Streams. • Evaluation of Energy Intensity, Carbon Impact and Cost of Energy per Product/Batch • Visualisation of selectable and interlinked KPIs to drive awareness of Energy Impacts at different levels in the Factory • Decision Support (What If) basis for proposed energy efficiency projects / changes in Production TEMPO MODEL Decision Support Visualisation KPIs TEMPO Engine Process Maps Standardised Data Energy Data Communication Interfaces Virtual Meters VSD PLC Production Operations

13. Process Map Approach Wait times to be added and additional value streams and/or processes to be mapped. Virtual and Simulated Meters being developed.

14. EnergyOptimisation A Multi-Objective Genetic Algorithm has being adapted to quantify variations in Total Energy & Total Production Time for a specific value stream. Decision Support: Used to indicate an optimum trade-off between Production throughput and Energy Intensity

15. Energy Modelling The ECLIPSE Energy Modelling Tool (developed by UU) for techno-economic analysis of power systems is producing simulated results based on a Value Stream Process Map and Production Data.

16. Smart Energy Network Generic Adapters being developed for Interoperable Virtual Meters from existing Industrial Control Networks, Energy Monitoring Systems, PLCs, VSDs and SCADA. Standardised DataSetsand Structures under Development. Lab-based Test Rig under construction

17. john.cosgrove@lit.ieThank YouQuestions ?