Energy costs are climbing, but many manufacturers still don’t know exactly where their energy is going on the shop floor. Without real-time monitoring, inefficiencies and waste often go unnoticed, driving up expenses and complicating sustainability efforts. Discover how targeted energy monitoring solutions can turn raw data into actionable insights for smarter, more efficient manufacturing.

Energy Monitoring Solutions Summary:

• Real-time energy monitoring exposes inefficiencies and waste in machine operations
• Integrating energy data with MES and ERP systems supports data-driven decisions
• Batteryless monitoring and automated analytics reduce downtime and operational costs
• Shoplogix IMS delivers actionable insights for continuous improvement and productivity gains

Why energy monitoring is a priority for manufacturers

Rising energy costs and sustainability goals have made energy usage a central concern for manufacturers. Yet, many facilities still struggle with high consumption, waste during machine idle times, and a lack of real-time visibility into where energy is going. Without clear data, it’s difficult to identify leaks, abnormal consumption, or opportunities for improvement.

Common challenges with energy usage on the shop floor

Most manufacturing plants face several persistent issues when it comes to energy management:

• Machines often run inefficiently, consuming more power than necessary
• Operators and managers lack real-time feedback on energy usage per process or machine
• Energy waste accumulates during idle or unproductive periods
• Abnormal consumption or leaks can go undetected for long periods
• Energy data is rarely integrated with production data, making it hard to link usage to output
• Tracking energy by machine or process is challenging without the right tools
• Many facilities still rely on reactive, rather than proactive, energy management

These challenges add up to higher operational costs, lost productivity, and missed sustainability targets.

How current energy monitoring solutions address these problems

Modern energy monitoring solutions are designed to tackle these issues head-on. Real-time monitoring systems use sensors and IoT devices to capture detailed energy data directly from machines and equipment. This information is then integrated with manufacturing execution systems (MES) and ERP platforms, allowing for a complete view of both energy consumption and production output.

Batteryless or low-maintenance monitoring devices are increasingly common, reducing the need for frequent servicing and ensuring continuous data flow. Advanced analytics platforms process this data to identify inefficiencies, triggering automated alerts when abnormal consumption is detected. Dashboards provide operators and managers with clear, actionable information, making it easier to spot trends and respond quickly.

Continuous improvement programs are supported by these insights, enabling teams to set targets, monitor progress, and adjust processes based on real-world data rather than assumptions.

Integrating energy data with production management systems

The value of energy monitoring increases significantly when it is linked with production data. By connecting energy usage to specific machines, lines, or shifts, manufacturers can pinpoint which operations are most energy-intensive and why. This integration also makes it possible to calculate energy cost per unit produced, supporting more accurate pricing and cost control.

When energy data is part of the broader MES or ERP environment, it becomes easier to correlate consumption with production schedules, maintenance events, and equipment performance. This holistic view supports smarter scheduling, targeted maintenance, and more effective resource allocation, ultimately reducing both energy waste and downtime.

Shoplogix IMS: Real-time, batteryless monitoring for continuous improvement

Shoplogix Intelligent Monitoring Solutions (IMS) is a notable example of how energy monitoring technology has advanced. The system delivers real-time, batteryless monitoring, capturing energy data directly from the shop floor without the maintenance overhead of traditional devices. This approach not only reduces downtime but also ensures a continuous stream of accurate data.

Shoplogix IMS integrates seamlessly with manufacturing execution systems, making it possible to analyze energy usage alongside production metrics. The platform’s analytics tools provide actionable insights, helping manufacturers identify where energy is being wasted and where improvements can be made. By supporting data-driven decision-making, Shoplogix IMS helps facilities lower operational costs, enhance equipment reliability, and boost overall productivity.

Implementation considerations for manufacturers

Adopting an energy monitoring solution requires a clear understanding of the facility’s existing infrastructure and operational needs. It’s important to assess which machines and processes are the biggest energy users and where data gaps exist. Choosing a system that integrates easily with current MES or ERP platforms will maximize the value of both energy and production data.

Training for operators and managers is also key. Teams need to understand how to interpret energy data, respond to alerts, and use dashboards to inform daily decisions. Ongoing support and regular reviews of energy performance ensure that the system continues to deliver value as operations evolve.

Final Thoughts on Energy Monitoring Solutions for Manufacturers

Energy monitoring on the shop floor is about building a foundation for smarter, more efficient manufacturing. With real-time, integrated solutions like Shoplogix IMS, manufacturers can move from reactive problem-solving to proactive, continuous improvement, turning energy data into a powerful tool for operational excellence.

What You Should Do Next 

Explore the Shoplogix Blog

Now that you know more about energy monitoring solutions, why not check out our other blog posts? It’s full of useful articles, professional advice, and updates on the latest trends that can help keep your operations up-to-date. Take a look and find out more about what’s happening in your industry. Read More

Request a Demo 

Learn more about how our product, Smart Factory Suite, can drive productivity and overall equipment effectiveness (OEE) across your manufacturing floor. Schedule a meeting with a member of the Shoplogix team to learn more about our solutions and align them with your manufacturing data and technology needs. Request Demo