VEXPLOR
View all solutions
Equipment/Infrastructure

FEMS (Factory Energy Management System)

Monitors and analyzes energy consumption of key factory equipment in real-time to maximize energy efficiency and reduce carbon emissions.

ISO 50001 (Energy Management System)
Start for freeView documentation
01

Are you facing these challenges?

Energy costs represent a significant portion of manufacturing costs, yet managing them systematically is far from easy.

You don't know exactly where energy costs are coming from

You know the total electricity bill, but you can't pinpoint which process, which equipment, or which time of day is consuming how much energy. With meters installed only at the building level, you can't calculate energy intensity by process or production line. When directives come down to cut energy costs, there's no evidence-based data to determine where to start.

Peak demand charges are driving up electricity costs

Exceeding contracted power capacity significantly increases base charges, yet there's no system to detect and respond to peak events before they happen. It's difficult for on-site staff to make immediate decisions about which equipment to shed or delay during peak periods.

Carbon emission reporting requires manual effort every time

Whether for K-ETS (Korea Emissions Trading Scheme) compliance or customer ESG requirements, carbon emission reporting is handled manually in spreadsheets. Collecting Scope 1 (direct emissions) and Scope 2 (electricity usage) data, applying emission factors, and accounting for renewable energy offsets is cumbersome and error-prone.

Proving the effectiveness of energy savings projects is difficult

You run savings projects -- LED replacements, inverter installations, HVAC optimization -- but quantitatively proving the actual savings is challenging. Calculating improvement against a baseline requires adjusting for external variables (temperature, production volume changes, etc.), and this process is complex.

Demand response (DR) participation is stuck at manual operation

You participate in the utility's DR program, but dispatch response, performance calculation, and settlement are all handled manually. Inaccurate CBL (Customer Baseline Load) calculations mean participation revenue falls short of expectations, or response windows are missed.

02

Here's how we solve it

Track energy consumption causes through sub-metering

Meters are registered in a hierarchical structure (Plant > Building > Process > Line > Equipment), and energy consumption data from each meter is automatically collected. Multiple protocols including MODBUS, BACnet, OPC-UA, MQTT, and REST API are supported, allowing existing installed meters to be connected as-is.

Parent-child meter summation is automatically validated (with configurable tolerance thresholds) to ensure metering data integrity. Energy intensity is automatically calculated by energy type (electricity, gas, steam, compressed air, water, fuel oil), department, and process, enabling specific identification of energy cost drivers.

Predict peak demand and respond automatically

Current demand is monitored in real time against contracted capacity, and when thresholds are predicted to be exceeded, automated response procedures are initiated. The peak response workflow (WF2) adjusts non-essential equipment operation according to a pre-defined load-shedding sequence.

When ESS (Energy Storage Systems) are available, a TOU (Time-of-Use) schedule-based strategy automatically charges during off-peak hours and discharges during peak hours. Hybrid operation of Li-ion batteries and ice thermal storage systems is supported, with SOH (State of Health) management for tracking ESS performance degradation.

POP (on-site) screens enable emergency peak demand load-shedding and manual ESS control, allowing on-site staff to respond immediately even when automated responses are insufficient.

Carbon emission reporting is automated

Emission factors (IPCC/national standards) are applied to energy consumption data to automatically calculate Scope 1 (direct emissions) and Scope 2 (electricity usage) emissions. Renewable energy generation performance, carbon credits, and offsets from PPA (Power Purchase Agreement)/REC (Renewable Energy Certificate) contracts are factored in to automatically calculate net emissions.

Four types of renewable energy contracts can be managed -- PPA, REC, Green Premium, and Corporate PPA -- with offset performance automatically aggregated per contract. Benchmarking capabilities enable comparison of your emissions against industry averages and best-in-class levels.

Energy baselines and performance indicators managed according to standard methodologies

Energy Baselines (EnB) and Energy Performance Indicators (EnPI) required by ISO 50006 are managed in dedicated tables.

During baseline establishment, normalization variables (temperature, production volume, operating hours, etc.) are identified and regression models are applied to adjust for energy consumption variations due to external factors. This enables quantitative measurement of actual savings project effects, isolated from external variables.

EnPI supports 3 types -- intensity-based, absolute, and statistical model -- configurable by boundary (total/process/equipment/building/line). Improvement rates are automatically calculated, tracking energy savings target achievement on a monthly/quarterly/annual basis.

Demand response (DR) is automated

The utility's DR program CBL calculation methods (Max4/5, High4/5, Average) are built in, automatically producing accurate customer baseline loads.

When a DR dispatch is received, load reduction is executed according to pre-defined response procedures (WF5), and compliance performance is automatically recorded. Settlement data is auto-generated and report forms are automatically prepared, reducing submission preparation time.

Energy audits and improvement projects are systematically managed

The energy audit workflow (WF3) manages the entire sequence from audit planning through execution, finding documentation, to report preparation. Findings from audits are automatically linked to improvement projects (WF4), ensuring the finding-to-action-to-verification flow is never broken.

Investment amount, estimated savings, actual savings, and ROI are tracked per improvement project, enabling objective evaluation of energy savings investment effectiveness.

03

Global Standards This Solution Follows

ISO 50001:2018 -- Energy Management System

Why does this standard matter?

Systematically managing energy costs requires a "measure > analyze > improve > verify" cycle. ISO 50001 defines this cycle as PDCA (Plan-Do-Check-Act) -- the international standard for energy management. For K-ETS compliance, customer ESG evaluations, and energy savings target management, ISO 50001 certification serves as objective evidence.

How is it applied in VEXPLOR FEMS?

ISO 50001 ClauseSystem ImplementationWhat It Means for Your Operations
4.1 Understanding the organizationEnergy meter hierarchy, energy type classification (electricity/gas/steam/compressed air/water/fuel oil), departmental allocation reflected in the data modelYou can understand where, how much, and in what form energy is being used across the entire organization
5.2 Energy policyEnergy target tables and KPI management providedEnergy savings targets can be established and tracked so policy becomes actionable goals, not just slogans
6.2 Energy Baseline (EnB)Dedicated table manages baseline period, normalization variables, regression model, R-squared, weather correction coefficientsWhen measuring savings, you can distinguish whether "power decreased because temperature rose" or "actual savings were achieved"
6.3 Energy Performance Indicators (EnPI)3 EnPI types (intensity, absolute, statistical model) configurable by total/process/equipment/building/line boundariesManagement can monitor plant-wide intensity while floor managers track process-level intensity
6.4 Energy targets/actionMonthly/quarterly/annual energy target setting with automatic achievement calculationTargets like "improve energy intensity by 5% this year" are automatically compared against actual data
8.1 Operational planning/control6 workflows (anomaly detection, peak response, energy audit, improvement project, DR response, ESS scheduling) automate operational managementPeak response, DR dispatch handling, and anomaly remediation are executed by the system, not by memory
9.1 Monitoring/measurement/analysisEnergy consumption records, daily aggregation, power quality (voltage/current/power factor/THD/imbalance ratio), anomaly detection performed automaticallyEnergy consumption data is automatically collected, aggregated, and analyzed, reducing manual reporting burden
9.2 Internal auditEnergy audit workflow (WF3) manages audit planning > execution > findings > reportingISO 50001 internal audits can be performed directly in the system, with findings automatically linked to improvement projects
9.3 Management review14 dashboard widgets, KPI trends, benchmarking reports providedManagement review energy status reports are available directly from dashboards without separate preparation
10.1 Nonconformity/corrective actionAudit findings automatically linked to improvement projects (WF3 > WF4)Prevents issues found in audits from being left unaddressed
10.2 Continual improvementImprovement project ROI tracking, EnPI improvement rate monitoringEnergy savings investments can be quantitatively proven in terms of actual returns

As you use the system, data essential for ISO 50001 certification (energy baselines, performance indicators, audit records, improvement results) naturally accumulates. The burden of separate documentation preparation for certification audits is reduced.

ISO 50006:2014 -- EnPI and EnB Methodology

Why does this standard matter?

A 5% reduction in electricity consumption doesn't necessarily mean real savings. External factors like temperature changes and production volume fluctuations must be adjusted to measure actual savings effects. ISO 50006 provides the specific methodology for establishing and managing Energy Baselines (EnB) and Energy Performance Indicators (EnPI). Compliance with this standard is essential for ISO 50001 certification.

How is it applied in VEXPLOR FEMS?

ISO 50006 RequirementSystem ImplementationWhat It Means for Your Operations
EnB establishmentBaseline period, data collection scope, and regression analysis model managed in dedicated tablesThe reference point for measuring savings is clearly established, and everyone can evaluate against the same standard
EnPI selection3 types supported: intensity, absolute, statistical modelYou can select performance indicators that match your energy management objectives
NormalizationNormalization variables (temperature, production volume, etc.) identified with correction coefficients appliedExternal factor variations in energy consumption are separated, extracting only the actual effects of savings projects
EnPI monitoringMonthly KPI tracking with automatic improvement rate calculationMonthly energy performance is reviewed with real-time progress tracking against targets
EnB adjustmentBaseline lifecycle (establishment > review > approval > active > adjustment > retirement) managed through workflowsWhen significant changes occur (production line expansion, process changes), baseline reset procedures are standardized

EN 16247 -- European Standard for Energy Audits

Why does this standard matter?

Energy management begins with accurately understanding the current state. EN 16247 provides a systematic methodology for energy audit planning, execution, and reporting. Under the EU Energy Efficiency Directive (EED), large enterprises must conduct energy audits every 4 years, and similar requirements apply domestically through the energy audit system.

How is it applied in VEXPLOR FEMS?

EN 16247 PartSystem ImplementationWhat It Means for Your Operations
Part 1 General requirementsEnergy audit workflow (WF3) manages the entire audit process: planning, execution, and reportingAudit procedures are embedded in the system, enabling consistent methodology-based audits
Part 2 BuildingsUtility monitoring (HVAC, lighting) tracks building energy usageBuilding-level energy consumption can be assessed. However, building energy simulation is not supported
Part 3 ProcessesPer-meter consumption analysis and process-level intensity calculationYou can identify which processes consume the most energy and track intensity trends
Part 5 Auditor competenceAuditor field exists. Dedicated competence management features are planned for future enhancementAudit performer records are available, but auditor qualification management currently requires separate handling

Note: Part 4 (Transport) is outside the scope of factory energy management and is not currently supported.

IEC 61968 -- Energy Management Information Exchange

Why does this standard matter?

Factory energy management systems must exchange data with various subsystems including meters, SCADA, and BMS. IEC 61968 defines a Common Information Model (CIM) for information exchange between energy management systems. Following this standard facilitates integration with diverse energy-related systems.

How is it applied in VEXPLOR FEMS?

IEC 61968 ElementSystem ImplementationWhat It Means for Your Operations
CIM Common Information ModelMeter-consumption-aggregation hierarchy designed to conform to the CIM modelEnergy data is managed in a standardized structure, reducing data transformation burden when integrating with external systems
Metering (AMI/AMR)5 protocols supported: MODBUS, BACnet, OPC-UA, MQTT, REST APIExisting meters can be connected regardless of protocol, enabling data collection without additional hardware investment
Demand Response (DR)3 tables (DR program, DR event, DR settlement) and DR response workflow (WF5) for end-to-end managementFrom utility DR dispatch through compliance performance calculation to settlement, everything is handled in a single system
Distributed Energy Resources (DER)Integrated management of renewable energy sources, ESS, PPA/REC contractsOn-site generation (solar, etc.) and ESS operation performance and renewable energy contract compliance are managed in one system

GHG Protocol -- Greenhouse Gas Emissions Calculation Methodology

Why does this standard matter?

For K-ETS, customer ESG evaluations, and CDP reporting, carbon emissions must be calculated according to GHG Protocol methodology. Accurately distinguishing Scope 1 (direct emissions) from Scope 2 (indirect emissions) and applying emission factors is fundamental to regulatory compliance and ESG response.

How is it applied in VEXPLOR FEMS?

GHG Protocol ElementSystem ImplementationWhat It Means for Your Operations
Scope 1 direct emissionsEmissions from on-site direct combustion (boilers, generators, etc.) are automatically calculated from energy consumption dataEntering energy usage automatically produces Scope 1 emissions, eliminating manual calculations
Scope 2 indirect emissionsIndirect emissions from purchased electricity are automatically calculatedElectricity usage and emission factors (IPCC/national standards) are linked for automatic tracking of electricity-related carbon emissions
Emission factor managementBoth IPCC and national emission factors supportedAppropriate emission factors can be applied for both domestic regulatory reporting and global reporting
Offset managementRenewable energy generation, carbon credits, PPA/REC contract offsets automatically factored into net emissions"Net emissions = emissions - renewable energy offsets - carbon credits" is automatically calculated, improving reporting accuracy
BenchmarkingComparison available against company/industry average/industry best-in-classYou can objectively assess where your carbon emission level stands within the industry
04

How It Differs from Existing Systems

Workflow Automation

Existing FEMS products excel at monitoring and analysis but have limited business process automation. VEXPLOR FEMS features 6 workflows (anomaly detection response, peak demand management, energy audit, improvement project, DR response, ESS scheduling) comprising 80 nodes, fully automating the detect > decide > act > verify process.

On-site (POP) Screens

Traditional FEMS products are designed around management dashboards, making them difficult to use directly on the manufacturing floor. VEXPLOR FEMS provides 6 POP screens enabling on-site staff to use touch interfaces for meter barcode scanning, emergency peak load-shedding, DR field response, and manual ESS control.

Localized for the Korean Power Market

The Korean utility's industrial electricity rate structure (TOU time-of-use pricing), DR system (CBL calculation methods), and K-ETS (emissions trading scheme) are built into the system. No separate localization work is needed for immediate application to domestic manufacturing sites.

Demand Forecasting AI

3 forecasting algorithms are supported -- LSTM, Prophet, and ARIMA -- with MAPE (Mean Absolute Percentage Error) tracking for continuous monitoring of forecast model accuracy. Confidence intervals are provided to enable decision-making that accounts for forecast uncertainty.

No-Code Extensibility

Beyond the standard energy management framework, you can add or modify metering points, analysis screens, report formats, and workflows specific to your plant's characteristics directly on the canvas. Compared to hard-coded traditional FEMS products, modification costs and lead times are significantly reduced.

05

How Does It Compare to Global Solutions?

The FEMS market includes global solutions such as Schneider Electric EcoStruxure, Siemens Energy Manager, Honeywell Forge, and ABB Ability. The table below compares coverage across major capability areas.

Comparison by Functional Area

Capability AreaSchneider EcoStruxureSiemens Energy ManagerHoneywell ForgeABB AbilityVEXPLOR FEMSWhat It Means for You
Energy MonitoringFull supportFull supportMostly supportedMostly supportedMostly supported (88% coverage)Multi-energy source, sub-metering, hierarchy, daily aggregation automation provided
Sub-MeteringFull supportMostly supportedMostly supportedBasic supportMostly supportedMeter hierarchy with parent-child summation validation (configurable tolerance)
Demand ForecastingFull supportMostly supportedFull supportMostly supportedMostly supported (82% coverage)LSTM/Prophet/ARIMA algorithms, MAPE tracking, confidence intervals. Real-time forecasting not yet implemented
Peak/DR ManagementMostly supportedMostly supportedMostly supportedBasic supportFull support (87-88% coverage)Peak prediction/response/impact analysis, DR CBL calculation (Max4/5, High4/5, Average), dispatch > compliance > settlement > reporting end-to-end automation
ESS OptimizationMostly supportedFull supportBasic supportMostly supportedMostly supported (85% coverage)Li-ion/ice thermal hybrid operation, TOU arbitrage optimization, AI scheduling, DR integration, SOH management
Carbon ManagementMostly supportedMostly supportedFull supportMostly supportedMostly supported (85% coverage)Scope 1/2 emissions, emission factor management, renewable energy offsets, PPA/REC, net emissions auto-calculation. Scope 3 not yet supported
ISO 50001Full supportFull supportMostly supportedBasic supportFull support (90% coverage)EnB/EnPI in dedicated tables, normalization variables, regression models, baseline approval workflow implemented
Energy AuditBasic supportBasic supportBasic supportLimitedMostly supportedFull audit process (planning > execution > findings > report) managed through workflow (WF3)
Improvement ProjectsBasic supportBasic supportMostly supportedBasic supportFull supportInvestment, estimated/actual savings, ROI tracking with automatic audit finding linkage (WF3 > WF4)
Utility ManagementFull supportFull supportFull supportFull supportBasic support (72% coverage)Compressed air/HVAC/steam/refrigeration/boiler monitoring available but optimization algorithms not included
Reporting/DocumentsMostly supportedMostly supportedMostly supportedBasic supportMostly supported14 dashboard widgets, KPI trends, benchmarking reports
POP/On-site ScreensLimitedLimitedLimitedLimitedFull support6 touch-optimized on-site screens (meter barcode scan, emergency peak shed, DR field response, manual ESS control) -- unavailable in traditional FEMS
Workflow AutomationBasic supportBasic supportBasic supportLimitedFull support6 workflows (80 nodes) fully automating detect > decide > act > verify

Where VEXPLOR FEMS Particularly Excels

  • Full Workflow Automation: 6 workflows with 80 nodes provide the most detailed business process automation among competitors. End-to-end automation from DR event response to ESS scheduling.
  • 6 POP/On-site Screens: Touch-optimized screens for manufacturing floor energy management are capabilities absent in traditional FEMS.
  • ISO 50001 Implementation Depth: The design that separates EnB/EnPI into dedicated tables with normalization variables and regression models is on par with Schneider and Siemens.
  • Integrated DR Program + Settlement: Fully reflects the Korean power market's demand response system (CBL, utility DR), processing dispatch > compliance > settlement > reporting in a single flow.
  • No-Code Extensibility: Tables, screens, and workflows can be freely extended on the canvas, significantly lowering customization costs compared to hard-coded legacy products.

Honest Assessment of Limitations

There are areas requiring enhancement compared to global products.

  • Utility Optimization (72% coverage): Monitoring of compressed air, HVAC, steam, refrigeration, and boilers is available, but utility optimal operation algorithms provided by Schneider/Siemens/Honeywell/ABB are not included. This is an area where global products commonly have strong expertise.
  • Significant Energy Use (SEU) Management (68% coverage): MES equipment linkage (equipment_id FK) exists, but dedicated features for in-depth per-equipment energy efficiency analysis are still limited.
  • Benchmarking Automation (70% coverage): Company/industry average/industry best comparison is available, but automatic collection of external benchmark data is not supported.
  • Cross-Solution Integration Depth: FEMS standalone feature completeness is high, but integration depth with EAM/MES and other solutions needs future strengthening.
  • Scope 3 Emissions: Supply chain/transport indirect emissions (Scope 3) are included in the mid-term development plan.
  • EN 16247 Part 4 (Transport): Transport sector energy audits are not supported.
06

Expected Benefits After Implementation

Evidence-Based Energy Cost Reduction

Once process-level, line-level, and equipment-level energy intensity is calculated, it becomes clear where energy costs originate. This data enables prioritizing savings opportunities and predicting investment returns. Energy cost reduction starts not with a target of "how much to cut" but with understanding "where and why costs occur."

Peak Demand Charge Reduction

Peak demand forecasting and automated response prevent contracted capacity overages, and ESS operation optimization reduces purchased power during peak hours. TOU arbitrage (off-peak charging > peak discharging) is a direct method of improving ROI on ESS investments.

Carbon Emission Reporting Effort Reduction

With automatic calculation from energy consumption data through to carbon emissions, the manual process of collecting data and processing it in spreadsheets for each reporting period is eliminated. Emission factor changes and renewable energy offset accounting are handled in the system, improving reporting accuracy and consistency.

Strengthened K-ETS/ESG Regulatory Compliance

Emission data, reduction performance, and renewable energy usage records required for emissions trading scheme compliance are automatically managed in the system. When responding to customer ESG supply chain evaluations, you can submit structured energy management performance data.

Increased Demand Response (DR) Participation Revenue

Accurate CBL calculations and automated response procedures improve compliance rates during DR participation and reduce settlement process errors. DR response history is systematically recorded for use in future participation strategy development.

Streamlined ISO 50001 Certification Preparation

Core elements of the energy management system (baselines, performance indicators, targets, audits, improvement projects) are naturally recorded during system operation. Separate documentation preparation for certification audits is reduced, and continuous improvement evidence can be demonstrated with data during renewal audits.

07

Solution Architecture Summary

ComponentScaleDescription
Data Model40+ tablesMetering, consumption records, aggregation, EnB/EnPI, carbon emissions, DR, ESS, utilities, etc.
Workflows6 (80 nodes)Anomaly detection, peak response, energy audit, improvement project, DR response, ESS scheduling
ScreensManagement screens + 6 POPDashboard (14 widgets), analysis screens, on-site touch screens
Global Standards4 built inISO 50001, ISO 50006, GHG Protocol, EN 16247 (partial)

Features Not Available in the Current Version

For transparency, here are the limitations of the current version.

  • Scope 3 Emissions Tracking: Supply chain and transport-related indirect emissions (Scope 3) are not yet supported. Included in the mid-term development plan.
  • Utility Optimization Algorithms: Monitoring of compressed air, HVAC, steam, refrigeration, and boilers is available, but algorithms for automatically calculating optimal operating conditions are not included.
  • SEU (Significant Energy Use) Dedicated Management: Dedicated features for SEU analysis required by ISO 50001 are included in the short-term development plan.
  • Real-Time Streaming Forecasting: Current demand forecasting is batch-based; real-time streaming-based forecasting is planned for future support.
  • Transport Sector Energy Audit: EN 16247 Part 4 (Transport) is not supported.
08

Cross-Solution Integration

VEXPLOR FEMS can operate standalone, but integration with the following solutions amplifies its effectiveness.

  • EAM Integration: Linking per-equipment energy consumption with maintenance history enables determining whether energy efficiency degradation is due to equipment aging and factoring energy perspectives into maintenance timing decisions.
  • MES Integration: Connecting production volume data with energy consumption data enables accurate energy intensity calculations and incorporating energy costs into production planning.
  • Digital Twin Integration: Visualize factory energy flows in a digital twin, and simulate energy impacts of equipment layout changes or process modifications before implementation.
  • SCM Integration: Accurately allocate energy costs to per-product costs, increasing cost structure transparency.

Try it yourself

Apply the FEMS (Factory Energy Management System) template on the canvas, and data models to screens are auto-generated.

Start for freeView detailed docs
VEXPLOR — Install an OS in Your Factory | Manufacturing AI Operating System