MES, SCADA and OPC in Industrial Automation: How AI Cracks Energy Efficiency

(Original article on Medium)

The integration of various systems is key to achieving streamlined, efficient, and sustainable operations in industry.

The important systems that drive automation and data exchange in manufacturing are Manufacturing Execution Systems (MES), Supervisory Control and Data Acquisition (SCADA), and Open Platform Communications (OPC). These systems, while distinct in their roles, often work together to provide control, monitoring, and optimization of industrial processes.

Data integration in an industrial manufacturing.

The Role of MES, SCADA, and OPC

Manufacturing Execution Systems (MES)

MES operates at a high level within manufacturing processes: it manages and optimizes production operations. It focuses on tracking production progress, managing workflows, and ensuring quality control. MES integrates with higher-level business systems like ERP (Enterprise Resource Planning). It offers a view of real-time manufacturing data. And it helps companies improve production efficiency and meet key performance indicators (KPIs).

How information flows throughout an automated process control.

Supervisory Control and Data Acquisition (SCADA)

SCADA focuses on real-time monitoring and control of industrial processes. It allows operators to visualize data, interact with machinery. Finally, it issues commands to devices such as valves, motors, and pumps. SCADA’s strength lies in its ability to provide immediate feedback and control. It enables facility operators to maintain smooth and safe operations.

Open Platform Communications (OPC)

OPC is not a control or management system like MES or SCADA. Rather this is a communication standard that ensures different systems and devices exchange data. OPC acts as the bridge between machinery, PLCs (Programmable Logic Controllers), sensors, and higher-level systems, i.e. SCADA and MES. It enables data to flow freely and securely between devices. It may come from different vendors or platforms.

Commonalities Between MES, SCADA, and OPC

Though MES, SCADA, and OPC serve different functions, they share several commonalities:

  1. Data Flow. MES relies on real-time data, often sourced from SCADA, to track production and ensure efficiency. SCADA relies on OPC to collect and send real-time data from sensors and machines.
  2. Industrial Automation. All three systems are central to the smooth operation of industrial processes. They play critical roles in modernizing and optimizing manufacturing environments.
  3. Integration. MES and SCADA are often integrated within a facility. OPC acts as the communication protocol, tying everything together. And it ensures data flows accurately between devices and systems.
  4. Real-Time Data. All these systems rely on real-time data to make decisions. And at different stages: for production monitoring (MES), process control (SCADA), or data exchange (OPC).
OPC flow from a client snapshot.

Enter BeChained: Automating Energy Efficiency

In the optimization of industrial processes, energy efficiency has become a top priority. Companies seek to reduce emissions, lower energy costs, and meet sustainability targets. This is where BeChained steps in. BeChained offers a solution that integrates with MES, SCADA, OPC in existing facilities. It connects with energy meters to create an automated loop for energy optimization.

How BeChained Integrates with Existing Facilities

BeChained leverages data from multiple sources. Namely, smart meters, MES systems, SCADA, and ERP platforms. It reduces energy use in real time in specific industrial processes. The key integration points include:

  • Energy Meters. BeChained gathers data from smart energy meters, per individual machine at the facility. Thus, it provides real-time insight into energy consumption patterns.
  • MES and SCADA via OPC. By connecting with MES and SCADA systems (through OPC), BeChained taps into process data. The most common information is machine’s settings, equipment status, environmental conditions, and more. So, it understands how different machines and processes are consuming energy. OPC ensures seamless communication between devices and systems, regardless of the manufacturer.
  • ERP Systems. BeChained integrates with ERP systems to consider production schedules. It reads resource planning and operational constraints. So, it balancea energy efficiency with production requirements.

The Closed-Loop System for Energy Optimization

  1. Data Collection. In real time, BeChained gathers data from meters (for energy use), SCADA (for machine control and process data), and MES (for batch information). OPC ensures smooth communication between these systems.
  2. Analysis and Optimization. The BeChained platform analyzes this data in real time to identify the optimal settings on machines in processes (such as air compressors, water pumps, or thermal processes). Then, it identifies how to reduces energy consumption, through an AI-powered intelligence. while maintaining production quality and efficiency. For example. It adjusts electric motor speed in a water pump, guaranteeing output pressure and flow in a water pump. In air compressors, it operates on pressure and flow at their most efficient levels. In exhaust fans, it tweaks rotation of motors, without compromising air quality.
  3. Feedback Loop. Once the optimal settings are identified, BeChained sends a feedback signal (via OPC or SCADA) to the machine controllers. Not only recommending, but also adjusting machine parameters automatically. This could involve adjusting valve positions, motor speeds, or other process variables to reduce energy use, without requiring human intervention.
  4. Automated Execution. It executes the optimized settings automatically through SCADA or OPC instructions, directly sent to machine controllers. This automation frees operators from repetitive and monotonous tasks. And it allows them to focus on more critical or creative decision-making processes. At the same times, it ensures energy-efficient operations.

Real-Time Energy Efficiency Without Operator Intervention

The key benefit of the BeChained platform is that it automates the energy optimization process. In traditional setups, operators must manually adjust equipment settings. This is time-consuming and often prone to human error. BeChained takes over this task. It continually optimizes processes. It improves energy saving, while maintaining operational efficiency.

High view of real-time process management.

This automation not only reduces energy consumption but also:

  • Lowers emissions by cutting unnecessary energy usage.
  • Improves operational efficiency by ensuring machines run at their most optimal settings.
  • Reduces human error by minimizing the need for manual adjustments and interventions.
  • Boosts productivity by freeing operators to focus on more complex tasks, rather than routine adjustments.

Conclusion

The integration of MES, SCADA, OPC, and BeChained provides a powerful solution for manufacturers. Net result: optimizing their energy use and reducing emissions.

By harnessing real-time data from meters, MES, and SCADA systems, BeChained creates a feedback loop that automates energy efficiency. Thus, it ensures machines always operate at their optimal settings.

This not only improves the sustainability of industrial processes, but also enhances overall operational efficiency.

So, allowing companies to meet their energy goals while maintaining high production standards.