Manufacturing industries, particularly energy-intensive sectors such as progressive die stamping (PDS), face increasing pressure to enhance energy efficiency and reduce environmental impact. This paper presents a case study of a small-to-medium enterprise (SME) in Poland, analyzing its energy consumption profile and identifying opportunities for improvement through the implementation of an Energy Management System (EMS). The study employed a mixed-methods approach combining 12 months of utility and production data with direct on-site observations. Results revealed an annual energy demand of 305.19 MWh and a facility-level Specific Energy Consumption (SEC) of 2.44 kWh per 1,000 parts. Key inefficiencies included significant idle-state energy use and limited monitoring granularity. To address these, a layered EMS framework is proposed, integrating sub-metering, real-time data processing, and visualization aligned with ISO 50001 principles. The proposed system is projected to reduce total energy consumption by 10–15%, optimize photovoltaic self-consumption, and establish a data-driven foundation for continuous improvement.

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A Preliminary Study on a Proposed Energy Management System Framework for a Progressive Die Stamping SME

  • Dawid Bogdanowicz,
  • Anna Woźna

摘要

Manufacturing industries, particularly energy-intensive sectors such as progressive die stamping (PDS), face increasing pressure to enhance energy efficiency and reduce environmental impact. This paper presents a case study of a small-to-medium enterprise (SME) in Poland, analyzing its energy consumption profile and identifying opportunities for improvement through the implementation of an Energy Management System (EMS). The study employed a mixed-methods approach combining 12 months of utility and production data with direct on-site observations. Results revealed an annual energy demand of 305.19 MWh and a facility-level Specific Energy Consumption (SEC) of 2.44 kWh per 1,000 parts. Key inefficiencies included significant idle-state energy use and limited monitoring granularity. To address these, a layered EMS framework is proposed, integrating sub-metering, real-time data processing, and visualization aligned with ISO 50001 principles. The proposed system is projected to reduce total energy consumption by 10–15%, optimize photovoltaic self-consumption, and establish a data-driven foundation for continuous improvement.