Edge
SWIFT-BOX
Capture and historise right at the machine.
Learn more →Case study · metalworking
Energy cost per order
instead of per site
Energy data from meters and machines joined with order data. Management sees unit cost including energy, production management sees load peaks in real time.
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01
Background: energy costs without attribution
A metalworking company with several linked plants knows its total energy consumption from the annual utility bill. What it does not know: how much energy a single manufacturing order consumes, which plant uses the most, and whether the load peaks are avoidable.
This is not unusual. In many manufacturing businesses, energy costs still appear as overhead and are distributed evenly across all orders. This distorts costing: energy-intensive orders appear cheaper than they are, energy-light ones are subsidised.
We installed meters at the critical consumers, integrated the readings into the existing data foundation and created a link to the manufacturing orders. The result: unit cost including energy share, updated daily, and a real-time view of load peaks that shows the production manager when multiple machines start up simultaneously.
€/unitenergy in the unit cost
Real timeload peaks visible
NIS2evidence covered
Questions about this project
How was energy data captured?
Via energy meters with M-Bus or Modbus interfaces at the main consumers. Edge gateways (SWIFT-BOX) read the meters at configurable intervals, historise the time series and forward them to the central data foundation, where they are joined with order data from the ERP.
Which standard requirements were addressed?
The energy management system covers parts of the ISO 50001 requirements and the NIS2 evidence obligations. NIS2 requires an inventory and monitoring of critical systems, including energy infrastructure. The captured meter data provides the necessary evidence in the data foundation.
Can energy monitoring be integrated into existing ERP systems?
Yes, that was the case here. Manufacturing orders come from the customer's SAP; energy data is attributed automatically on order completion without a member of staff having to post manually. The interface follows the ISA-95 layers. Which ERP is used is secondary as long as it provides order data via an interface.
Make energy cost per order visible.
We connect your energy data with order data and give you the basis for defensible costing.
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