Case study: Red Dot Corporation

We helped Red Dot Corporation gain a deeper understanding of energy usage across the production process, which meant they could make changes to improve efficiency and monitor progress along the way.

The customer

Red Dot Corporation produces premium heating, ventilation, and air conditioning (HVAC) units and components for a wide range of heavy duty off-road vehicles. They are a global supplier to a wide range of markets including, construction, agriculture, military, and trucking industries.

The challenge

Red Dot were looking to gain a deeper understanding of how much energy they consume once production is underway. The company had no means apart from looking at their monthly energy bill to visualise energy usage.

Particularly interested in improving productivity and energy efficiency, they were keen to make changes to their operational process but had no way of checking whether new changes would make a positive impact on their overall business performance and consumption.

As a company, they had made some minor changes to infrastructure and lighting to become more energy efficient but wanted to apply this to their manufacturing processes to enable them to work smarter.

“Now I have data, I can see how much energy the tanks currently consume. They get switched off at the end of the week and are on automatic timer to switch back on Sunday afternoon. I am interested in changing the process so they operate using their temperature controller and seeing if this makes a difference to the energy they can use. I can use the AEMS trends to check whether this has made any impact.”

IT & Facilities Manager, Red Dot Corporation

The results

Increased visibility across the production line and operational processes – AEMS helped the user better understand energy usage across the different HVAC manufacturing processes. As a result, they were able to gain greater visibility of how specific machinery within their process contributes to the overall energy consumption.

Greater efficiency and ability to monitor change – Visualisation of usage across the manufacturing process enabled the user to trial new ways of working and easily monitor the impact this had on their total consumption. They were able to gain insight into how the manufacturing line and specific machinery was operating. As a result, they were able to make changes to their process and track progress.

“Without the raw data for that zone I couldn’t check whether changes to processes make a difference. So being able to use AEMS and view my data, I can have more visibility and control to try out some new processes to see if it will make a difference.”

IT & Facilities Manager & Red Dot Corporation

How we did it

  • Zone monitoring analytics identified how much energy was being consumed by specific machinery in the manufacturing process. Hot water tanks that degrease and prepare the metal surface prior to powder coating were monitored for over a month, in this time they contributed 25% to the overall energy consumption.
  • Operating mode analytics allowed the facilities manager to understand how energy is split across business as usual activities and manufacturing. Highlighting the distribution of energy across operating modes helped them to see what the normal activity is and when usual activity starts and changes over the day.

“The usage report from the provider is too manual. Having the usage readily accessible on the dashboard automatically is really helpful. I can look at data that is already analysed and this saves me time, which is a good benefit.”

IT & Facilities Manager & Red Dot Corporation