Energy efficiency is increasingly becoming a strategic competitive factor for manufacturing companies. Rising energy costs, regulatory requirements, and sustainability targets are also increasing the pressure to make energy flows in the plant transparent and actively manage them. With autinityE3, Schaeffler Digital Solutions provides a software solution that records and visualizes energy consumption in detail and serves as the basis for data driven efficiency measures. This enables targeted optimization of processes and equipment.
The challenge: Lack of transparency and untapped savings potential
In many plants, energy consumption is still recorded only at the overall plant level. As a result, it remains unclear exactly where electricity and heat are used or wasted. Individual machines or processes may cause unnecessarily high consumption without being visible.
Typical challenges:
- No transparent display of equipment consumption
- Missing comparability between identical machines
- High base load outside production times
- Insufficient analysis of auxiliary processes such as dryers or heating systems
These blind spots prevent targeted optimization. Savings potential remains unused, and energy efficiency measures cannot be evaluated or verified.
The solution: Energy monitoring and analysis with autinityE3
autinityE3 captures and analyzes energy data from machines, equipment, and infrastructure systems in real time. This solution example covers four specific use cases: integration of a PV plants, optimization of the oven door, reduction of the base load on weekends with Eco Mode, and reduction of dryer running time and temperature. All four are based on autinityE3 as the software for energy monitoring and analysis. The software provides a cockpit with individually configurable widgets and diagrams that clearly display trends, comparison values, and energy feed-in.
Integrating a PV system
Existing photovoltaic systems are integrated into autinityE3 as an energy source. The dashboard provides performance charts, generated energy, energy surpluses, self consumption, and grid feed-in, as well as the degree of self sufficiency. It also enables KPI based evaluations.
Comparing identical ovens
With autinityE3, consumption data of identical paternoster ovens is displayed in the dashboard for direct comparison. The analysis identifies deviations and traces the cause back to the oven door design. The door is then adapted accordingly.
Weekend shutdown and Eco Mode
The base load of presses is visualized through autinityE3. This forms the basis for implementing an Eco Mode in the PLC, which reduces the load outside of production times and can be rolled out across the entire facility.
Dryer optimization
In the phosphating system, the target temperature of the hot air dryer is lowered and the runtime control is adjusted. autinityE3 supports configuration, monitoring, and validation of the measure.
Integration and scalability
autinityE3 can be integrated step by step into existing facilities. New processes or machines can be connected easily, data points can be added flexibly, and dashboards can be configured individually.
The result: Transparent data, sustainable production
With autinityE3, Schaeffler Digital Solutions establishes the foundation for transparent, data driven energy management. The following results come from the four use cases described above:
Results at a glance:
- Comparison of identical machines: direct identification of outliers as a basis for targeted measures
- PV integration: full transparency on feed-in, generated energy, surplus, and degree of self-sufficiency
- Comparison of identical machines: direct identification of outliers as a basis for targeted measures
- PV integration: Transparency regarding feed-in, energy produced, energy surplus, and degree of self-sufficiency
- Oven door optimization: significant energy savings depending on design and use
- Eco Mode: Reduction of base load outside production times
- Dryer optimization: Savings through reduced temperatures and optimized running times
The modular structure supports a gradual rollout from pilot projects to global deployment. Schaeffler Digital Solutions provides flexible implementation models and ensures that every measure measurably contributes to the company’s sustainability and efficiency strategy.
