The top 7 energy indicators in energy management

What role does the ERP system play?

Energy indicators alone do not save energy. They serve as a starting point for optimizing an energy system and create the objectification and visualization of energy targets. Typically, energy indicators are formed on the basis of data from various systems. Depending on the KPI, energy data from the energy monitoring system, production data from the MES or business parameters from the ERP system are required to create and monitor energy performance indicators. In practice, Excel spreadsheets are often used due to a lack of interfaces between the systems.

What are the most important energy performance indicators for small and medium-sized companies?

We present the key energy figures that interest our customers the most.
To this end, we asked 20 small and medium-sized manufacturing companies from various sectors. The survey asked respondents to rate the importance of key energy figures for their own company.

Overall result of the survey: How important are the following energy indicators in your company?

Top 7:

#1 - Energy consumption per machine:

According to our customers, the most important key energy figure measures energy consumption per machine.
This key figure can be used to compare different machines in particular.
For example, if a machine has a defect and consumes more energy than usual, this can be read off using this relative key figure.

#2 - Share of individual machines in total energy consumption:

The key figure in 2nd place also looks at energy consumption per machine. In contrast to the first place, here the consumption per machine is set in relation to the total energy consumption.
This allows a good distribution of the energy used across the machines to be determined and adjusted if necessary.
Optimization measures can be developed on the basis of this energy indicator, for example by taking a closer look at the machines with the largest share of total consumption.

#3 - Energy costs in relation to production costs:

In 3rd place, the energy costs are set in relation to the manufacturing costs.
This makes it clear how much energy consumption contributes to the general production costs.
This key figure plays an important role in optimizing production costs.

#4 - Energy consumption per process:

Most processes in a company are unthinkable without the use of energy (in whatever form). Putting processes in relation to the associated energy consumption often leads to new insights. Individual processes are seen from a completely new perspective.
Particularly energy-intensive processes can be examined more closely thanks to this relative energy indicator and, ideally, optimized directly.

#5 - Share of energy costs in total costs:

Similar to the energy key figure in 2nd place, this relative key figure puts two variables in a rather unusual relationship. For many companies, this relationship is of no significance. However, energy consumption, and therefore energy costs, can account for a large proportion of total costs. Especially in times of high energy prices, a look at this key figure can lead to frightening insights.
By analyzing this important key figure, optimization measures such as reducing loads or changing energy procurement can be planned and then implemented.

#6 - Energy consumption per output:

Behind number 6 - "energy consumption per output" - is the amount of energy required to produce a part or batch (or similar). This is particularly important when considering the distribution of costs per product. Energy is often not considered as a cost item in the cost calculation, which can lead to surprises when costs are analyzed retrospectively.
It is therefore also important to consider energy as a cost item, e.g. for the calculation of fixed costs per part.

#7 - Energy consumption per unit produced:

The last place in the ranking describes the same case as #6 with the only difference that here only the individual part level is considered, instead of also larger orders or batches.
This relative energy figure should not be neglected for a correct cost calculation.

What do we see in the results of the survey?

On the one hand, monetary indicators were rated as important, such as energy costs in relation to production costs and the proportion of energy costs in total costs. These energy indicators enable an economic evaluation and are important parameters for controlling an industrial company.