Energies, Vol. 18, Pages 6133: Integration of Key Performance Indicators (KPI) Taxonomy and Energy Efficiency Analysis in the Aluminium Industry Using Industry 4.0 Technologies
Energies doi: 10.3390/en18236133
Authors:
Andrzej Pacana
Karolina Czerwińska
Lucia Bednárová
Zuzana Šimková
The energy transition in the aluminium industry is crucial, as its processes are among the most energy-intensive. In this context, KPIs (Key Performance Indicators), defined as quantitative measures for assessing the effectiveness and efficiency of processes, are an essential tool for identifying energy losses, monitoring the results of optimisation measures, and supporting the achievement of sustainable development goals. The purpose of the study was to develop a KPI taxonomy model that would enable the identification and monitoring of energy efficiency at the process level in aluminium industry companies, using Industry 4.0 tools (visualisation screens). As part of the selection of indicators, a literature review, surveys, and in-depth interviews were conducted. A classification of indicators corresponding to energy-intensive stages of production was proposed, which allows precise tracking of energy efficiency at each stage of production. The practical contribution of the study is the construction of visualisation screens that enable real-time monitoring of KPIs and support optimisation decisions. This approach integrates energy management, smart manufacturing, and predictive maintenance, enabling comprehensive and sustainable energy management. The results indicate the need for further research on the development of energy KPIs to improve efficiency, and their implementation in the aluminium industry should be supported through guidelines, tools, training, and pilot projects.