🏭 Smart Downtime Management

Unplanned Downtime Energy Optimization

OPC-UAModbus TCPPLC/SCADAMQTT

Current Draw562 kW

Optimized483.3 kW

Savings Potential78.7 kW

Annual Savings€14,891

Energy Saved82,729 kWh/yr

CO₂ Avoided19.3 t/yr

Energy comparison

Before vs. After FYXO

Without FYXO

Downtime power draw562 kW

Auxiliary systemsAll at 100%

TTU / AMS / HydraulicRunning idle

Wasted energy (12% downtime)590774 kWh/yr

Operator actionManual / none

With FYXO

Downtime power draw483.3 kW

Auxiliary systemsManaged per state

Avoided idle load−78.7 kW

Energy saved82,729 kWh/yr

Annual savings€14,891

CO₂ avoided19.3 t/yr

Restart readiness< 240s

OEE impactNeutral / protected

Machine states

Production Cell Status

Cell A — Aluminium Die-Cast

Die-Cast #1 (800T)

Running

Machine Power95 / 120 kW

Auxiliary Power55 kW

Cycle Time55s

TTU 18kWAMS 15kWHYDRAULIC 22kW

Die-Cast #2 (1250T)

Unplanned Down

Machine Power165 / 180 kW

Auxiliary Power80 kW

Cycle Time72s

Downtime Duration8min

TTU 24kWAMS 18kWHYDRAULIC 30kWVACUUM 8kW

CNC Trim Press

Micro-Stoppage

Machine Power38 / 45 kW

Auxiliary Power12 kW

Cycle Time35s

Downtime Duration1min

AMS 7kWCOOLING 5kW

Die-Cast #3 (630T)

Running

Machine Power75 / 90 kW

Auxiliary Power42 kW

Cycle Time48s

TTU 12kWAMS 12kWHYDRAULIC 18kW

24h analysis

Cycle & Downtime Analysis

OEE 99.5%

Total Cycles (24h)5,983

Normal Cycles5,968

Micro-Stoppages12

Unplanned Downtimes3

Avg Cycle Time53s

Energy Intensity8.59 kWh/cycle

Downtime %4.4%

OEE99.5%

Auxiliary systems

TTU / AMS / Hydraulic Power Usage

TTU (6-circuit) (TTU)No action

Full: 18 kWStandby: 2.7 kW

Compressed Air Supply (AMS)No action

Full: 15 kWStandby: 2.3 kW

Hydraulic Unit (HYDRAULIC)No action

Full: 22 kWStandby: 3.3 kW

TTU (8-circuit) (TTU)−14.4 kW

Full: 24 kWStandby: 3.6 kW

Compressed Air Supply (AMS)−12.6 kW

Full: 18 kWStandby: 2.7 kW

Hydraulic Unit (HYDRAULIC)−15 kW

Full: 30 kWStandby: 4.5 kW

Vacuum System (VACUUM)−7.6 kW

Full: 8 kWStandby: 1.2 kW

Air Blow-off System (AMS)−2.1 kW

Full: 7 kWStandby: 1.1 kW

Coolant Circulation (COOLING)No action

Full: 5 kWStandby: 0.8 kW

TTU (4-circuit) (TTU)No action

Full: 12 kWStandby: 1.8 kW

Compressed Air Supply (AMS)No action

Full: 12 kWStandby: 1.8 kW

Hydraulic Unit (HYDRAULIC)No action

Full: 18 kWStandby: 2.7 kW

Pilot scenario

Industrial Configuration & Assumptions

Pre-pilot prototype

Production Cell

IndustryAluminium die-casting

Machines3 die-cast + 1 CNC trim

Cell power~560 kW total

Shift pattern3-shift / 24h

Controlled Auxiliaries

TTUTool tempering units (4–8 circuit)

AMSCompressed air supply

HydraulicClamping unit pumps

Vacuum / CoolingDie cavity & coolant

Integration & Safety

Machine PLCOPC-UA

TTU / AMSModbus TCP

Control principleReduce idle auxiliary load

Safety constraintOEE & quality protected

Solution brief

FYXO Smart Downtime Management

Problem

Industrial machines consume full auxiliary energy (TTU, compressed air, hydraulics) during unplanned downtime — typically 12% of operating hours. This energy is entirely non-productive.

Solution

FYXO detects machine production cycles via power signature analysis, classifies downtime events in real time, and safely transitions each auxiliary system to a lower-energy state while preserving restart readiness.

Impact

Up to 60% reduction in non-productive energy consumption during downtime. Estimated €15k+ annual savings and ~19 tonnes CO₂ avoided per production cell. Zero impact on OEE, throughput, or product quality.

Deployment

Software-first approach. Integrates with existing PLC/SCADA infrastructure via OPC-UA and Modbus TCP. No hardware modifications required. Deterministic rules today, extensible with ML cycle classifiers from real production data.