Revolutionising the Manufacturing Landscape:
Enhancing Energy Efficiency with IIoT and MES

Embracing Industrial IoT and Manufacturing Execution Systems for Energy Optimisation

Setting the Stage: Energy Efficiency in Manufacturing

The high-stakes game of global manufacturing is fast becoming an arena where the need for energy efficiency is a crucial player. In an era where the cost of energy is high and environmental concerns are mounting, optimisation of energy consumption has transformed from a competitive advantage into an absolute necessity. Manufacturers are keenly aware that energy savings translate into cost savings, improved regulatory compliance, enhancing customer relationships, and a reduced carbon footprint.

28th September 2023

The Industrial IoT Path to Energy Management

Leading the charge on this front is the Industrial Internet of Things (IIoT) - an interconnected web of smart sensors and devices that aid manufacturers in managing their energy consumption. By collecting energy use data from individual machines on the shop floor in real-time, traditionally opaque areas of energy flow become transparent. Through IIoT, manufacturers can precisely monitor where energy is used, where it's wasted, and where conservation measures can be implemented.

Unmasking Manufacturing Execution Systems

The integration of MES and IIoT introduces an innovative spin to energy management in manufacturing. Through IIoT, useful data can be extracted in real-time about every aspect of the manufacturing process. This data, when fed into the MES, creates a live, comprehensive view of energy consumption across the production chain. The symbiosis of IIoT and MES allows manufacturers to make informed decisions, optimise their production schedules and machine operations, and minimise energy waste.

Consider an energy-guzzling machine - thanks to the IIoT, this energy hog is no longer invisible. MES recognises the anomaly, and predictive maintenance measures can be activated to tackle the issue before it cascades into a significant energy drain or machine breakdown.

Real-world Implications

The advantages of integrating IIoT and MES technologies in manufacturing are not just projections or hypothetical scenarios; they have been borne out in real-world applications. Numerous companies across industries have successfully leveraged this integration to optimise their operations and reduce costs. Although the exact percentage of energy cost reduction might differ from one organisation to another, the consensus is that MES and IIoT implementation contributes significantly to operational efficiency.

For instance, a plethora of companies, according to a Forbes article, have reported major enhancements in their operations post-integration of IIoT and MES. Another report from Automation World highlights various tales of businesses successfully implementing MES to their advantage.

While we might not have a clear-cut case of a specific manufacturer reducing energy costs by ‘x’ percent, the over-arching narrative remains the same: IIoT and MES integration is a powerful tool for manufacturing firms to optimise their operations, improve energy efficiency, and boost productivity.

In conclusion, while the quantifiable results might differ, the qualitative benefits of integrating IIoT and MES in the world of manufacturing are evident and are bringing about a significant transformation in the industry.


  1. Forbes - How The IIoT And MES Work Together To Enhance Operations
  2. Automation World - A Tale of Three Clients and Their Journeys to MES

Challenges on the Horizon

The pathway to a seamlessly integrated MES and IIoT system is studded with challenges. These range from concerns around cybersecurity to overcoming hurdles related to technology integration. Every new technology, especially ones that dramatically change the practice, necessitates significant employee training in order to fully utilise the intended benefits.

However, these roadblocks are navigable. Selecting secure, standards based IIoT devices, conducting rigorous cybersecurity protocols, and establishing comprehensive employee training regimes can turn these challenges into stepping stones.

The Future: Sustainable, Intelligent, and Energy-Efficient

Looking ahead, the future of energy management in manufacturing with IIoT and MES appears promising. Further integration of AI and machine learning with these technologies will refine predictive capabilities and optimise energy consumption more granularly. As the journey towards a sustainable, intelligent, energy-efficient manufacturing industry gains momentum, an era of interconnected, energy-optimised, and environmentally conscious manufacturing is well within our reach. Something FactoryIQ are leading the way on.

Key Takeaway

The road to energy efficiency in manufacturing is not an easy one. By adopting a well-integrated Manufacturing Execution System compatible with Industrial IoT, manufacturers can gain comprehensive control over their production activities, enhancing not just efficiency but also productivity and profitability.

How FactoryIQ Can Help

This is where FactoryIQ steps in, offering a user-friendly system that bridges the gap between manufacturing resource planning and shop floor activities. FactoryIQ takes data from your existing MRP/ERP and creates an optimal schedule for work flowing through the factory based on due dates and resource availability.

Incorporating real-time monitoring capabilities, FactoryIQ’s Monitor device provides live status updates of all jobs and assets while facilitating operators to start or stop jobs as needed. Additionally, the system's analytics calculate key metrics, including Overall Equipment Effectiveness (OEE), and On Time In Full (OTIF), allowing manufacturers to identify and address bottlenecks and inefficiencies rapidly.

FactoryIQ encourages the integration of IIoT and MES, extending manufacturers a powerful tool for harnessing the potential of digital manufacturing, advancing productivity, and significantly improving energy management. With FactoryIQ, your journey towards an energy-efficient, sustainable, and future-proof manufacturing industry is secured. From enterprise-level corporations to middle-market players and SMEs, FactoryIQ provides a doorway to a greener, efficient, and more profitable future.