Integration of Energy Management Systems with Manufacturing Execution Systems for Industrial Efficiency and Sustainability

In recent years, rising energy costs, increasing environmental concerns, and the drive for sustainable production have placed energy management at the forefront of industrial challenges. The volatility of energy prices, combined with regulatory pressures for reduced carbon footprints, has driven companies to seek more efficient and cost-effective production strategies. In this context, integrating Energy Management Systems (EMS) within Manufacturing Execution Systems (MES) emerges as a promising solution, enabling real-time monitoring, analysis, and optimization of energy consumption across production processes. This thesis explores the integration of EMS into MES to enhance industrial energy efficiency. The research begins with a comprehensive literature review, analyzing current EMS functionalities, the latest trends in energy monitoring, optimization, and predictive analytics. The investigation highlights the gaps and opportunities in existing EMS solutions, focusing on their integration with operational data and production workflows. The study then aims to a practical implementation framework using AgileFactory, a commercially available MES. Through this integration, the thesis proposes a methodology to embed energy management capabilities into the MES architecture, leveraging real-time data acquisition, production phase monitoring, and energy performance analysis. The proposed methodology is validated through a use case at a company specializing in leather and textile treatments for the fashion industry. The use case outlines the process of data collection, energy performance indicator definition, and correlation analysis between energy consumption and production variables such as working cycles, machine operating time. The analysis concludes with a performance assessment, comparing predicted and actual energy consumption, identifying inefficiencies, and recommending strategies for energy cost reduction and process optimization. The results demonstrate how the integration of EMS within AgileFactory MES not only improves energy visibility but also supports data-driven decision-making for sustainable production practices. This thesis contributes both theoretically and practically by bridging the gap between energy management theory and industrial application. The developed implementation framework and use case findings provide a replicable model for other industries seeking to enhance their energy efficiency through MES-EMS integration. The proposed approach aligns with modern industrial strategies for digital transformation, sustainability, and continuous improvement, highlighting the role of digitalization in driving energy-aware manufacturing processes.