Leveraging our expertise in digital transformation, data-driven energy management and IT-OT integration, the initiative integrated FactoryTalk® Energy Manager™ to enable real-time energy monitoring, predictive analytics and actionable insights.
This initiative goes beyond providing a powerful solution for optimizing energy use, reducing costs and ensuring business continuity—it highlights how DX drives both efficiency and environmental responsibility. By implementing these innovations, Rockwell’s APBC has become a global model for industrial innovation and is positioned to realize the vision of becoming a World Economic Forum Lighthouse Factory.
A Strategic Approach to Energy Efficiency and Sustainability
Singapore’s reliance on imported energy makes electricity costs a significant operational challenge. With Rockwell’s APBC facility operating 24/7, energy consumption is a critical factor in both cost control and sustainability.
The facility faced several hurdles in achieving optimal energy efficiency, including escalating energy costs, lack of real-time usage visibility, outdated infrastructure requiring modernization, manual data collection processes limiting employee productivity and the need for secure IT-OT integration across systems.
To address these challenges, Kalypso helped Rockwell select the best-fit internal digital solutions, providing an informed, neutral perspective on available options. This ensured that Rockwell’s energy management strategy was both effective and aligned with corporate sustainability goals and future expansion plans.
At the core of this transformation was FactoryTalk® Energy Manager™, a digital energy management platform designed to monitor, analyze and optimize energy consumption in real time. As an IT-OT convergence solution, it provides energy and production insights at the plant, process area, line and machine levels.
Kalypso played a critical role in implementation, working closely with Rockwell’s APBC leadership, plant operations and IT teams to ensure seamless deployment. This collaboration enabled APBC to achieve immediate energy efficiency gains while also laying the foundation for predictive analytics and AI-driven decision-making in future phases.
Implementation Highlights
- Real-time Energy Monitoring & Analytics — Enabled precise tracking of energy usage trends and identification of efficiency opportunities.
- Seamless IT-OT Integration — Engaged Rockwell’s IT team early in the process to ensure secure, scalable integration with enterprise systems.
- Legacy System Adaptation — Installed energy meters and sensors on older equipment, ensuring a non-disruptive transition to digital monitoring.
- Data-Driven Decision Making — Linked energy consumption with production planning to enhance operational efficiency.
- Scalable Architecture — Deployed a hybrid cloud model, allowing for secure, enterprise-wide data access and future AI-driven optimizations.
Lessons Learned
This project underscored several key lessons for manufacturers looking to enhance energy efficiency through digital transformation.
Early IT-OT Collaboration Drives Success —
Engaging IT teams from the outset ensures smooth integration and scalability.
Leadership Buy-In is Essential —
Strong executive support accelerated full-scale adoption, avoiding pilot purgatory.
Workforce Upskilling Enhances ROI —
Training employees to leverage digital tools accelerates adoption and maximizes efficiency gains.
Energy Efficiency and Productivity Work Together —
System design is integral to ensuring operational improvements and sustainability initiatives complement one another.
Foundations for the Future
Through the successful implementation of this robust, scalable energy optimization solution, we have positioned Rockwell’s APBC to expand AI-driven predictive energy optimization, replicate success across global facilities and deepen sustainability integrations. This initiative not only enhances operational efficiency and cost savings but also reinforces Rockwell’s leadership in sustainable industrial automation - demonstrating how digital transformation shapes the future of industrial operations and Kalypso’s role as a leading digital advisory and implementation partner.
- AI-driven predictive energy optimization, leveraging machine learning to further reduce energy waste.
- Expansion to additional global sites, replicating the success of the Singapore facility across Rockwell’s global manufacturing footprint.
- Deeper integration with enterprise-wide sustainability initiatives, ensuring alignment with long-term environmental goals.
