ONE PROBLEM, DECODED.
Energy waste,
made visible.
A real-time system that detects abnormal energy use and recommends operating settings that bring the process back within its desired range.
TWELVE MONTHS · MULTIPLE PRODUCTION LINES · ONE FACTORYDETECT THE GAP / CORRECT THE SETTING
01 / THE PROBLEM
The setpoint is not
the process.
Ceramics manufacturing is energy intensive, with natural gas accounting for a substantial part of operating cost. Small inefficiencies can persist unnoticed across equipment and production lines.
The relevant signal lives in the difference between intended settings and observed behavior. During certain periods, those discrepancies produced materially higher energy consumption.
02 / THE METHOD
Detect the gap. Recommend the setting.
Detection alone was not enough. The system also had to identify a better operating point without violating production constraints.
We combined temperature, pressure, energy consumption, and controllable set parameters from individual equipment across multiple lines.
The deployed models identify abnormal energy behavior, infer the settings required to return consumption to its desired range, and surface both the anomaly and recommendation through a real-time operational view.
- Temperature
- Pressure
- Energy consumption
- Controllable set parameters
- 01
Observe
Connect equipment-level process and consumption data.
- 02
Compare
Measure the gap between desired parameters and actual behavior.
- 03
Recommend
Find corrective settings within the operation's constraints.
- 04
Integrate
Deliver anomalies and setpoint guidance in real time.
03 / THE RESULT
Less energy. Same operating reality.
15%
excess energy identified
up to this level during anomalous periods5%
lower energy use
expected overall reduction under live validationLIVE
decision support
anomaly detection and setpoint guidanceThe system turns energy efficiency from a retrospective report into an operational decision: detect the excess, identify the cause, and recommend the next setting.
04 / YOUR PROBLEM