Maximize ROI through OEE Optimization and Energy Management in MES/EMS Systems

Introduction: The Era of Smart Energy Management

In the age of Industry 5.0, where energy efficiency becomes a key differentiator, manufacturing enterprises face unprecedented challenges. According to the new EU Directive 2023/1791 on energy efficiency, member states must achieve an average annual energy savings rate of 1.49% between 2024–2030. This means that companies must radically rethink their approach to energy management.

A crucial tool in this transformation is the optimization of the OEE (Overall Equipment Effectiveness) index through intelligent energy management in MES-class systems. In both Industry 4.0 and 5.0, OEE plays a key role in ROI planning, reliability, and production stability.

Regulatory Foundations: EU Directives as a Catalyst for Change

Legal obligations for enterprises
Under the new law, energy management systems will become mandatory for large energy consumers (exceeding 85 TJ of annual energy consumption). Enterprises consuming more than 10 TJ will be required to conduct an energy audit and prepare an action plan. This is not just a compliance requirement but also a strategic opportunity to gain a competitive advantage.

Impact on industry
The directive requires the public sector to lead by example: EU public institutions must reduce their total final energy consumption by at least 1.9% annually. The private sector, though less restricted, must prepare for similar standards in the near future.

Industry 5.0: A New Paradigm of Energy Efficiency

Human at the center of sustainable production
The concept of Industry 5.0 combines human-machine collaboration, sustainability, and resilience. Unlike Industry 4.0, which focused on automation, Industry 5.0 places humans at the center of processes while maximizing energy efficiency.

Technological pillars of Industry 5.0
Industry 5.0 leverages IoT, AI, and data analytics to control energy consumption at every stage of production. These technologies enable:

Reduction of energy losses by 15–30% through real-time monitoring
Cost optimization with demand forecasting
Automation of energy management processes

OEE as a Tool for Energy Optimization

Classical formula and its evolution
OEE consists of three components: Availability, Performance, and Quality. Standard formula:

OEE = Availability × Performance × Quality

World-class OEE reference value: 85% (90% availability, 95% performance, 99% quality).

Extending with an energy component: OEEE
A pioneering approach is OEEE (Overall Equipment Energy Effectiveness), which considers the energy intensity of production processes. This allows for:

Holistic efficiency assessment
Identification of energy-intensive processes
Energy cost optimization in performance context

Business benefits
Optimization of two robotic welding lines generated 2,500,000 PLN in profits — proving how systematic OEE improvements deliver measurable ROI.

MES Systems in Energy Management: Solution Analysis

Omnimes: Polish Innovation in Industry 5.0
The OmniMES system by Multiprojekt represents a flagship Polish approach to next-gen MES. OmniMES applies Big Data to process and analyze massive volumes of production data.

Key functionalities:

Signal state detector – real-time monitoring
Planogram – bottleneck identification
Scheduling module – optimal resource utilization
Analysis module – root cause analysis of downtimes
OEE/KPI module – customized efficiency reporting

Technology architecture

Non-relational databases for trillions of records
MQTT protocol for high-speed data transfer

Benefits: scalability, real-time performance, reliability.

OmniEnergy: The future of energy management
Multiprojekt develops OmniEnergy, based on the OmniMES engine, presented at the Energy Management Conference (March 2025), signaling readiness for commercialization.

Predicted features:

Integration with EMS per EU directive
Real-time energy cost analysis
Load profile optimization
Energy demand forecasting
CO₂ emissions reporting

Comparative Analysis of MES Systems

Criterion	Omnimes	Wonderware/AVEVA	SAP MII
Implementation time	3–6 months	12–24 months	18–36 months
License cost	Competitive	High	Very high
Energy management	Native support	Add-on modules	Requires integration
Data scalability	Big Data (MongoDB)	Traditional SQL	SAP HANA
ROI	12–18 months	24–36 months	36–48 months

Key advantages of Omnimes:

Native Industry 5.0 support
Integrated energy management
Local Polish support
Flexible architecture

ROI of Energy Optimization: Business Cases

For a mid-size plant (20 TJ/year):

Energy cost: ~2.4M PLN/year
Potential savings: 360K–1.2M PLN/year
MES implementation cost: 150K–300K PLN
ROI: 4–16 months

Additional benefits: compliance, ESG reputation, resilience, readiness for future regulations.

Implementation Roadmap

Audit & planning (months 1–2) – energy audit, SCADA/PLC analysis, ROI goals.
Technical implementation (months 3–5) – IoT meters, SCADA/PLC integration, MES servers, dashboards.
Optimization & continuous improvement (6+ months) – predictive load management, AI-driven recommendations, energy storage integration.

Future Trends

PV integration with production forecasting
Energy storage optimization
Microgrids with island mode
Vehicle-to-Grid for EV fleets
AI-powered predictive maintenance, demand response, carbon footprint optimization

Strategic Recommendations

Short-term: Energy audits, MES selection, OEEE adoption, team training
Mid-term: 85% OEE with energy component, 20–30% energy cost reduction, ISO 50001 certification
Long-term: Full Industry 5.0 transition, carbon neutrality, monetization of flexibility

Conclusion: Energy as a Competitive Advantage

In Industry 5.0, smart energy management via MES is no longer optional but a business imperative.

Key takeaways:

EU push – regulations enforce adoption
Technology readiness – OmniMES offers native support
Proven ROI – 20–50% savings with 12–18 month payback
Competitive advantage – early adopters lead the market

The OmniEnergy system by Multiprojekt, built on the OmniMES engine, positions Polish enterprises as leaders in industrial energy transformation.

Maximize ROI through OEE Optimization and Energy Management in MES/EMS Systems

Martin Szerment