Spanish company Gestamp is a one of the world’s leading suppliers to the most important car manufacturers, offering the design, development, and production of innovative metal assemblies and parts. The company is represented in 20 countries and produces body parts, undercarriages, and mechanical components that lead to safer and lighter cars. Gestamp has a total of 97 industrial plants and 12 research and development centers. Nine more plants are currently under construction.
Energy consumption in the factories is constantly growing. Consistently optimizing consumption offers significant savings potentials.
The goal was to use a common platform to shape the behavior of all of Gestamp’s machines and devices based on real-time data so they could work as efficiently as possible. This would significantly reduce energy consumption and also cut CO2 emissions.
Siemens’ energy efficiency platform uses big data to optimize energy consumption and is already in operation in Gestamp factories in Spain, Germany, Great Britain, France, and Poland. Data acquisition devices were installed in the plants to collect about 40 million data points per hour. The data are transferred via the cloud to the platform, which is managed by the Siemens Smart Grids Control Center in Seville, Spain. The solution enables Gestamp to evaluate and optimize the power and gas consumption of all its factories in real time.
Its defining algorithms based on consumption patterns identify and warn about any energy malfunctions in the equipment. The energy consumption data can be processed using data analytic tools to define predictive maintenance, manage production processes, and forecast energy consumption based on future production requirements. The equipment’s behavior can be modeled so that it runs as efficiently as possible and in a coordinated way.
The optimization of plant consumption resulting from the data analyses and the solutions offered by this platform have allowed Gestamp to save almost 45 Gwh in the past 12 months. This substantial figure results in a payback period for the investment of less than three years. The cloud-based energy efficiency platform from Siemens can collect and process data in high resolution.
In addition to collecting and processing information, the platform can also correlate energy consumption data with other variables, like data from production, and it will detect energy inefficiencies and offer solutions to correct them. The platform thus facilitates a deeper understanding of plant operation and provides a reliable foundation for well-informed decisions.
Another benefit for Gestamp is high cost transparency and the implementation of the energy efficiency platform with no investment required. The system is financed by Siemens Financial Services, and the only costs are operational costs as a monthly service fee.