Three factories, one unit of production, one outlier

Background

A manufacturer operates comparable factories making the same product with the same equipment. Their energy bills differ, but each total covers the work done at that site. Our comparison starts by bringing energy readings and production counts together so the team can account for how much each factory produces.

The problem

A larger bill can accompany higher output. Looking at the totals alone leaves the team unable to separate that difference from a change in operating efficiency. The factories need a common basis for comparison before anyone can identify which site deserves attention or explain why its energy use stands apart.

How we found it

We use identical metering points at each facility and bring in production counts for normalization. A shared dashboard compares energy per unit of production across the sites. That lets the team review the same measure for the same output, with the underlying energy and production readings available together.

What changed

The normalized comparison identifies an outlying factory using more energy per unit than the comparable sites. The team can rank the facilities on a common measure and focus the next investigation. The dashboard shows where the difference sits; the operational reason for that difference remains something to examine at the facility.

The lesson

We keep the production input with the energy measurement. It makes the comparison useful to the people who have to explain the difference and decide what to check next. As operating conditions change, the team can return to the same measure and see whether the gap persists. That gives reviews across facilities a consistent starting point for discussing performance and following the effect of subsequent work.