IEK ERM

IEK ERM

A service for analyzing and visualizing data of technological processes and energy resources, based on machine learning technologies.
This service provides asset optimization and integration with enterprise management automation systems (ERP) and real-time data acquisition and processing systems (SCADA).

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  • Comprehensive
    optimization
  • Internal and external
    expertise
  • Data-driven
    solutions
  • Reliable solutions

Sources of production losses

The product's cost structure is heavily impacted by systemic inefficiencies, including material waste that causes equipment wear and downtime, high energy expenses from poor consumption patterns and a lack of monitoring, direct losses from defects, and an inability to make informed decisions without proper process data analysis.

  • Resource waste and unplanned downtime

  • Equipment breakdowns due to non-compliant specifications or raw material overconsumption

  • Direct costs of production waste

  • Inability to analyze production and energy data due to the lack of a dedicated system

  • Production costs account for a large share of the total product cost

  • Elevated energy expenses caused by inefficient consumption patterns, uneven equipment utilization, and high utility rates

Foresight and Efficiency

  • Energy Management and Forecasting

    • ML‑load forecasting

      Machine learning algorithms analyze historical data and weather conditions to accurately predict energy consumption and optimize work schedules (reducing costs by 15–25%)


    • Energy consumption forecasting subsystem

      Electricity consumption forecasts for participation in the Wholesale Energy Market and assessment of overpayments based on AMI meter readings

  • Process Modeling and Optimization

    • AI-based process modeling

      Modeling of continuous and discrete production processes using Artificial Intelligence helps identify optimization potential and develop algorithms to achieve target indicators


    • Integration with APS

      Using real production data in conjunction with the existing Automated Production Control System helps to adaptively respond to changes, incorporate real data into planning, and build an inventory management system

  • Production Quality Assurance

    • Computer vision

      The computer vision system helps improve product quality and respond faster to quality degradation. Automatic defect detection and production process optimization enable immediate sending of defective products for rework

  • Predictive Analytics

    • IoT + ML models

      IoT sensors combined with ML models predict equipment component wear (e.g., pump bearings), reducing downtime by an average of 30–40%

Value for Key Roles

Chief Energy Officer

Ensuring uninterrupted equipment operation through early warning of deviations. A set of ready-made reporting forms with customization options helps analyze peak loads and efficiently redistribute energy consumption.

Chief Engineer

Assistance in preventing accidents through predictive analytics to reduce unplanned downtime. Real-time energy consumption data allows for prompt adjustment of equipment operation parameters, enhancing the stability and reliability of the production process.

Business Analyst

Detailed tracking of energy consumption across workshops, sections, and down to individual equipment. This enables pinpointing energy waste ("leaks") and leverages predictive analytics for optimized planning.

Production Planner

A single platform resolves disputes between production and energy teams by using data on unplanned downtime to synchronize line scheduling.

Chief Executive Officer

Achieving compliance with international standards (ISO 50001) and ESG criteria to enhance customer and partner loyalty, as well as meeting the requirements of Federal Law No. 261 «On Energy Saving» and avoiding penalties from regulatory authorities.

IEK ERM includes databases of typical energy-saving measures and is integrated with evaluation indicators in accordance with the following requirements:

  • GOST R ISO 50001-2012 «Energy management systems. Requirements and guidance for use» (clause 6.2 — energy efficiency planning);

  • ISO 50006:2014 «Energy baseline and energy performance indicators» (for comparison with industry standards).

The functions of the IEK ERM product aimed at improving energy efficiency allow:

1. Comparing the enterprise's key energy efficiency indicators (EnPI) with industry benchmarks (e.g., specific energy consumption per unit of production in accordance with EN 16247-1:2021).

2. Evaluating the effectiveness of measures based on standards, including:

  • Energy intensity reduction (kW·h/t);
  • Equipment load optimization (OEE ≥ 85% according to the APQC standard).

To enhance and implement the IEK ERM product, an individual program is developed, which includes:

  1. 1. Goal Setting:
    • Setting EnPI based on benchmarks (e.g., energy intensity ≤ 0.15 kWh/unit of production).
  2. 2. Implementation of Measures:
    • Implementation of standard solutions from the database (modernization of control systems, installation of frequency converters).
  3. 3. Monitoring and Analysis:
    • Comparison of actual indicators with planned ones (clause 9.1 of GOST R ISO 50001).
  4. 4. Corrective Actions:
    • Review of goals after energy audit (clause 10.2 of GOST R ISO 50001).

The system provides:

  • Energy cost reduction by 12-18% within 2 years (in accordance with the EnergyStar benchmark);
  • Compliance with GOST R ISO 50001 requirements (confirmed by audit).

Documentation is prepared according to GOST 2.105-95, including data diagrams and energy efficiency reports.

Let's work together

We seek PLC producers and providers of ready-to-use/configurable control cabinets
for integration into our standardized solutions portfolio
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