Optimize Factory Performance with Real-Time Monitoring, Analytics & Reporting
The Energy Efficiency Monitoring and Analysis System (E²MAS) is an advanced industrial energy management system developed by A*STAR (SIMTech) to help manufacturers optimize energy use across machines and facility systems. With granular machine-level energy monitoring (EMONS), E²MAS serves as an advanced industrial energy analytics system, transforming raw data into actionable insights that drive cost reduction, operational efficiency and sustainability.
What Is E²MAS?
E²MAS delivers machine energy monitoring (EMONS) and advanced analytics to identify inefficiencies, abnormal consumption patterns and improvement opportunities. By combining real‑time monitoring with analytical intelligence, E²MAS serves as the foundation of an AI‑based energy management system approach for industrial operations.
The E²MAS operates through three core functional pillars to ensure tangible improvements in energy efficiency:
1. Monitor
Access a mobile dashboard providing real-time energy efficiency monitoring for all major equipment.
2. Analyse
Benchmark your current energy performance against your “historical best” to identify gaps and hotspots.
3. Report
Generate comprehensive energy efficiency achievement reports with a single click for management review or regulatory reporting.
How E²MAS supports Energy Efficiency in Manufacturing?
Assess equipment’s energy usage in real time and identify hotspots of excessive energy usage.
Real‑Time Energy Monitoring(EMONS)
E²MAS tracks electricity usage across machines and facility equipment in real time, displaying the data on a dashboard. This allows operations teams to see energy performance instantly instead of relying only on monthly utility bills.
Machine Energy Analysis
Intelligent Hotspot Detection
Using historical best‑performance benchmarks, E²MAS identifies energy hotspots and abnormal spikes. These insights support faster root‑cause analysis, strengthening overall energy control systems within the factory.
Actionable Energy Analytics
Performs causal analysis to identify contributing factors behind energy inefficiencies, supporting engineers in fine-tuning machines and processes.
Energy and Regulatory Reporting
Compile energy data to provide to provide structured reports to track performance, identify usage patterns, and support regulatory reporting requirements.
E²MAS Implementation: Before vs. After Comparison
See the measurable impact of E²MAS on manufacturing operations. The table below highlights key performance improvements before and after implementation.
Feature
Before E²MAS Implementation
After E²MAS Implementation
Energy Consumption
Carbon Footprint
Data Visibility
Reporting Effort
| Feature | Before E²MAS Implementation |
After E²MAS Implementation |
| Energy Consumption |
Limited detection of hotspots or excessive usage. | Up to 20% reduction in total energy consumption. |
| Carbon Footprint |
Manual or difficult assessment of greenhouse gas emissions. |
Up to 20% reduction in carbon emissions with live tracking.
|
| Data Visibility |
Hidden energy gaps and poor equipment oversight. |
Up to 80% increase in visibility of machine-level energy efficiency.
|
| Reporting Effort |
Time-consuming manual data collection for management. |
One-click automated report generation for instant review.
|
Frequently Asked Questions (FAQs)
What equipment is E²MAS designed to monitor?
E²MAS is designed to monitor factory machines such as CNC machines, moulding machines, heating equipment and similar production machinery. It enables granular Machine Energy Monitoring and real-time tracking of energy consumption, providing insights that help you optimise your operations and support an industrial energy management system.
How can businesses benefit from E²MAS?
Key advantages of E²MAS for machine-level energy monitoring:
– Monitor energy performance and utilisation of machines and facility equipment in real time
– Capture energy consumption patterns across your facilities
– Identify machine with high energy consumption and drive optimistic for energy efficiency
– Compare machines to find more energy-efficient operations and optimise processes
– Support energy and greenhouse gas reporting with actionable insights and standardised reports
What makes E²MAS different from a standard industrial energy monitoring(EMONS) system?
E²MAS is a data-driven industrial energy management system developed by A*STAR, designed to go beyond standard meters by linking energy data to machine performance. It enables Machine Energy Monitoring to track energy consumption at the equipment level, providing insights into efficiency and identifying hidden energy losses that standard systems may overlook.
How does E²MAS help to reduce operational costs and energy waste?
By using advanced energy control systems, E²MAS identifies equipment “hotspots” and anomalies in real-time. This industrial energy management system allows you to benchmark performance against your “historical best,” driving up to 20% reduction in waste and emissions while keeping your facility within its optimized power budget.
Does E²MAS require major changes to existing factory systems?
No major changes are required to core production systems. E²MAS works by connecting power meters and data collection devices to selected machines and facility equipment to capture real-time energy data. This allows you to implement E²MAS progressively without disrupting day-to-day operations.
Can E²MAS support carbon reporting and ESG reporting in Singapore?
E²MAS generates structured energy and emissions data that can support internal reviews and regulatory reporting. You can use this data as part of a carbon reporting solution and ESG reporting process, helping track and manage energy consumption at the machinery level.
What is value-adding vs non-value-adding machine time?
Value-adding time is when your machines are actively producing output, while non-value-adding time occurs when they are powered or running without output. Identifying both helps you improve productivity, increase equipment utilization, and reduce wasted energy by targeting idle running, delays and loss time.
What are energy consumption hotspots and why are they important?
A hotspot is a machine, component, or operating period with unusually high power draw versus expected levels. Identifying hotspots reduces energy cost and risk by exposing abnormal consumption, inefficiencies, and early fault signs so maintenance and optimization efforts can be focused where they deliver the biggest impact.
