A review of energy simulation tools for the manufacturing sector

Manufacturing is a competitive global market and efforts to mitigate climate change are at the forefront of public perception. Current trends in manufacturing aim to reduce costs and increase sustainability without negatively affecting the yield of finished products, thus maintaining or improving profits. Effective use of energy within a manufacturing environment can help in this regard by lowering overhead costs. Significant benefit can be gained by utilising simulations in order to predict energy demand allowing companies to make effective retrofit decisions based on energy as well as other metrics such as resource use, throughput and overhead costs. Traditionally, Building Energy Modelling (BEM) and Manufacturing Process Simulation (MPS) have been used extensively in their respective fields but they remain separate and segregated which limits the simulation window used to identify energy improvements. This review details modelling approaches and the simulation tools that have been used, or are available, in an attempt to combine BEM and MPS, or elements from each, into a holistic approach. Such an approach would be able to simulate the interdependencies of multiple layers contained within a factory from production machines, process lines and Technical Building Services (TBS) to the building shell. Thus achieving a greater perspective for identifying energy improvement measures across the entire operating spectrum and multiple, if not all, manufacturing industries. In doing so the challenges associated with incorporating BEM in manufacturing simulation are highlighted as well as gaps within the research for exploitation through future research. This paper identified requirements for the development of a holistic energy simulation tool for use in a manufacturing facility, that is capable of simulating interdependencies between different building layers and systems, and a rapid method of 3D building geometry generation from site data or existing BIM in an appropriate format for energy simulations of existing factory buildings

Manufacturing System Energy Modeling and Optimization

World energy consumption has continued increasing in recent years. As a major consumer, industrial activities uses about one third of the energy over the last few decades. In the US, automotive manufacturing plants spends millions of dollars on energy. Meanwhile, due to the high energy price and the high correlation between the energy and environment, manufacturers are facing competing pressure from profit, long term brand image, and environmental policies. Thus, it is critical to understand the energy usage and optimize the operation to achieve the best overall objective. This research will establish systematic energy models, forecast energy demands, and optimize the supply systems in manufacturing plants. A combined temporal and organizational framework for manufacturing is studied to drive energy model establishment. Guided by the framework, an automotive manufacturing plant in the post-process phase is used to implement the systematic modeling approach. By comparing with current studies, the systematic approach is shown to be advantageous in terms of amount of information included, feasibility to be applied, ability to identify the potential conservations, and accuracy. This systematic approach also identifies key influential variables for time series analysis. Comparing with traditional time series models, the models informed by manufacturing features are proved to be more accurate in forecasting and more robust to sudden changes. The 16 step-ahead forecast MSE (mean square error) is improved from 16% to 1.54%. In addition, the time series analysis also detects the increasing trend, weekly, and annual seasonality in the energy consumption. Energy demand forecasting is essential to production management and supply stability. Manufacturing plant on-site energy conversion and transmission systems can schedule the optimal strategy according the demand forecasting and optimization criteria. This research shows that the criteria of energy, monetary cost, and environmental emission are three main optimization criteria that are inconsistent in optimal operations. In the studied case, comparing to cost-oriented optimization, energy optimal operation costs 35% more to run the on-site supply system. While the monetary cost optimal operation uses 17% more energy than the energy-oriented operation. Therefore, the research shows that the optimal operation strategy does not only depends on the high/low level energy price and demand, but also relies on decision makers’ preferences. It provides not a point solution to energy use in manufacturing, but instead valuable information for decision making. This research complements the current knowledge gaps in systematic modeling of manufacturing energy use, consumption forecasting, and supply optimization. It increases the understanding of energy usage in the manufacturing system and improves the awareness of the importance of energy conservation and environmental protection