Assessing performance 

• Set up a spreadsheet to calculate the predicted kWh for a given production volume using the PCL.
• Determine the volume of material processed in the month (through the nozzles) and calculate the predicted energy usage.
• Determine the actual energy usage for the month.
• Compare the predicted energy usage to the actual energy usage.
• If the actual energy usage is less than the predicted energy usage then the site performed better than it has done historically - find out what the site did right and do more of it.
• If the actual energy usage is more than the predicted energy usage then the site performed worse than it has done historically - find out what the site did wrong and do less of it.

Weekly data collection gives faster feedback to production departments on how to improve. For plastics processing, it is best to use ‘kg’ as a reference for the production volume but it is also possible to use ‘parts’ or any other convenient measure of production provided the product mix doesn’t vary greatly. Recording kWh/kg as a process efficiency measure on a monthly basis will lead to inaccurate conclusions due to the effect of production volume changes.

Budgeting

The PCL can also be used to provide a model for energy budgeting. Use the forecast sales volume to produce a forecast production volume (in kg) and use the PCL to predict the energy usage. This links energy use directly to the sales budget and to the accounting system. Integrating energy use into the accounting system is a vital element of controlling energy costs.

The PCL can be used to assess a site’s performance:

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