01
Client Profile & Background
A large-scale manufacturing company in Bekasi, Indonesia, operates a 50-hectare facility producing automotive components. The plant runs 24/7 with over 2,000 employees and consumes an average of 15 MW of electricity monthly. The facility includes multiple production lines, HVAC systems, compressed air networks, and a central chiller plant. The company has a dedicated IT and facilities team but lacked a unified energy monitoring system. Energy costs accounted for 30% of operational expenses, and the company was targeting a 15% reduction to meet corporate sustainability goals. The existing monitoring relied on manual meter readings and periodic audits, which were inefficient and error-prone.
02
Technical Challenge
The manufacturing plant faced several technical challenges: First, manual energy data collection led to a 48-hour delay in identifying anomalies, causing 12-hour backup failures in critical cooling systems. Second, the facility had over 200 electrical panels and 50 HVAC units, but only 10% were monitored, leaving 90% of energy usage invisible. Third, power quality issues, such as voltage sags and harmonics, caused 5% production downtime monthly. Fourth, the compressed air system had leaks accounting for 25% of total air loss, but detection required shutting down lines. Finally, the company needed to comply with Indonesia's Ministerial Regulation No. 14/2012 on energy conservation, requiring a 20% reduction in energy intensity by 2025.
03
Implemented Solution
Intilogy deployed a Hikvision Energy Industrial Monitoring solution comprising 150 Hikvision DS-2TD2637B-10/P thermal cameras for temperature monitoring of electrical panels and motors, 100 Hikvision energy meters (e.g., DDSU666) for sub-metering at each production line, and 50 environmental sensors for humidity and temperature. Data is aggregated via Hikvision's iVMS-4200 AC software, integrated with the existing server and storage infrastructure. The system uses AI analytics to detect anomalies, such as a 10°C rise in a motor bearing, and triggers alerts. Additionally, the solution integrates with hyperconverged infrastructure for scalable data processing. For compressed air monitoring, we installed 20 ultrasonic leak detectors, reducing detection time from 8 hours to 15 minutes. The entire system is backed by backup and disaster recovery solutions to ensure data integrity.
04
Results & ROI
Within six months, the manufacturing company achieved a 22% reduction in energy consumption, saving IDR 4.5 billion annually. The RPO for energy data improved from 48 hours to real-time, and downtime due to power quality issues dropped from 5% to 0.5%. The compressed air leak detection program saved IDR 800 million per year. The thermal cameras detected three potential fire hazards early, preventing costly equipment damage. The company also achieved compliance with energy regulations, avoiding potential fines. The ROI was realized in 10 months, and the solution scaled to two additional facilities. Integration with cybersecurity measures ensured data protection, and the system's analytics provided actionable insights for continuous improvement.
