ZF GROUP CUTS PLANT POWER CONSUMPTION BY UP TO 15% WITH JANITZA

Project location
All locations with significant energy consumption

Year of implementation
2019-2024

Application
Energy Monitoring Solution

Hardware
Level 1: UMG-512-PRO Level 2: UMG 96-PA and UMG 801 Level 3: UMG 806

Software
GridVis®

Service
Project planning Delivery of hard- and software Project based installation (on request) Project commissioning Service support and training

REQUIREMENT
With 168 production sites in 32 countries and 19 main development centers in 9 countries, the ZF Group is one of the world’s leading automotive suppliers. ZF continually strives to enhance the efficiency of its global production sites. Sustainability is a core component of ZF Group‘s strategy, with goals such as achieving complete climate neutrality by 2040. To minimize their environmental impact, conserve resources, and improve their bottom line through efficient energy management, the ZF Group decided to implement an energy management system in accordance with the international standard ISO 50001. Previously, the lack of detailed data on their energy consumption made it difficult for them to track their sustainability efforts and goals. They were unable to monitor the progress of their mandatory sustainability targets for electricity, gas, compressed air, and water consumption. The only data available came from monthly energy bills, reported up to two months after the energy was consumed, which made it impossible to take timely countermeasures. Real-time, detailed data from their plants was not available to the ZF Group.
SOLUTION
The ZF Group selected Janitza as a trusted partner for smart energy and power quality solutions. With Janitza’s assistance, they established real-time data analytics through an Energy and Power Management System (EPMS) across their plants’ power distribution levels 1-3, meeting ISO 50001 requirements. At Level 1 (infeed level), they are deploying the UMG-512- PRO to monitor infeed with an on-site display. At Level 2 (distribution), they are using the UMG 96-PA to monitor single feeders and the UMG 801 for multiple feeders as standard. At Level 3 (machine level), the UMG 806 is preferably used to monitor single or multiple machines. Other Janitza meter types will be used depending on the application. Janitza’s EPMS software, GridVis®, is employed throughout their plants to track key figures and energy consumption in real-time.

BENEFIT
By using this real-time monitoring strategy, the ZF Group reduced energy costs and collected essential data for tracking sustainability efforts. The implementation of a load management system cut electricity consumption at their plants by up to 15%, enabling the ZF Group to set more ambitious sustainability targets, such as measuring their CO2 footprint at the product level. Janitza’s GridVis® supports their future growth, including the planned implementation of a cloud-based Digital Manufacturing Platform (DMP) in their plants.




