Throughout the deployment of the mai environmental suite, our clients have experienced first hand the value of our measure-analyze-improve methodology. As organizations strive to reduce risk and achieve compliance, the following case studies are instructive and provide keen insight into best practices and effective management of environmental programs.
Check out our case studies below for more information
IMPROVING WASTE WATER LICENSE COMPLIANCE AND OPERATIONAL EFFICIENCIES
Solution:
The mai™ application suite was selected as a solution to address the unique challenges within this waste water treatment facility. The plant deployed the mai™ Waste Water module to gather real-time analysis of when and where problems were occurring. The various control instruments at the waste water treatment facility (pH, temperature, dissolved oxygen, inflow and outflow volumes) were connected into the PLC network.
Using mai™, the plat was able to effectively capture relevant real time plant performance data, including upper and lower parameters. Leveraging an integrated SCADA application, we were able to capture important trending and visual display of the results. mai'stm ubiquitous web-based front end facilitated easy access to the information required to ensure license compliance and accelerate operational efficiencies remotely from its home office environment, including outside hours security.
Key Benefits To Client
The waste water treatment plant recognized significant benefits from the use of the mai™ application suite. The most significant benefit was the real time visualization of working parameters that allowed plant personnel to view and more importantly respond and correct any impending irregularities. As a result, the waste water treatment is now operating within its license conditions.
Improving Resource Usage, Energy Efficiency and Awareness
Our Solution:
This major manufacturer employed the maitm application suite to help effectively manage plant information and gain the intelligence needed to run the plant more efficiently. With mai™, the manufacturer was able to display real time information from production area to office environment and establish standard run rates for filling equipment. PLC code was written to monitor production units per minute. The user friendly web interface of mai™ provided a seamless dashboard for the operator to record reasons for manual stoppages and corrective actions taken.
Key Benefits To Client
Using the mai™ application suite, the manufacturer saved time and money and gained significant efficiencies in the overall management of the plant facility. Specifically, the plant manager now had the ability to measure manual stoppages to the nearest second and categorize them accordingly. All stoppage reasons identified were categorized as quality, operational, IT, Engineering etc. for better focused responses.
Hourly efficiency tables were populated to show daily live performance providing real time intelligence for the plant manager. Also, the plant manager now has the ability to display for supervisors and management actual plant conditions such as stopped /running /cleaning conditions.
An overall increase in production efficiency of 18% was realized during the first 6 months alone. Specific improvement plans to address bottleneck areas were implemented to further improve efficiencies on a continual basis. Remedial actions could be implemented more quickly by Engineering through monitoring of the live data.
Waste Water Compliance & Operational Efficiency
Our Solution:
The mai™ application suite was deployed side by side with an existing PLC network. The company installed individual meters for water, electricity and gas at strategic locations around the site. maitm was used to analyze and deliver to relevant personnel daily, weekly, monthly and year to date information in a timely manner. Through mai'stm functionality, the company was able to establish maximum and minimum limits and deliver rapid notification to relevant personnel when certain limits exceeded. This system was coupled with an energy monitoring system and SCADA system for trend analysis.
Key Benefits To Client
The goal of the mai™ application suite is to help companies Measure Analyze and Improve their operations and save both time and money. Using the maitm application suite, the company was able to collect important trend analysis showing actual loads which allowed them to resize existing compressors to meet minimum load requirements.
The company was able to track outside hours and plant energy usages for the first time, which led to the shedding of all non essential loads. This benefit alone resulted in significant savings.
Also using the mai™ application suite, the company was able to monitory ccompressed air usage which allowed leaks to be detected and repaired , again leading to significant savings.
Finally, the client was able to display energy usage in actual units as well as an equivalent amount to assist with the energy awareness training that was undertaken. Overall cost of Energy monitoring package was paid for after 8 months.