At Gorenje Orodjarna, the DENiM project focuses on the digital twin of machining processes to improve planning, design, programming and energy efficiency in tool manufacturing. As a toolmaker for the home-appliance and automotive industries, we operate energy-intensive machining processes such as milling, grinding, EDM, WEDM, turning and laser processing.
Through the DENiM platform we increased the digitalisation of our operations: monitoring energy consumption, developing digital twins of key manufacturing processes, and applying advanced analytics to optimise machine utilisation and production planning. The pilot supports data-driven decisions that reduce machine idle time, energy consumption, tool wear, scrap rates and overall production costs.
The solutions deployed at our pilot include custom data connectors linking MODBUS energy and air-consumption sensors with production data from our ERP, the DENiM data platform, an energy monitoring dashboard, a machine-learning energy prediction pipeline, the Gorenje Operations Logger, and the Sustainable Production Planner — an AI tool that optimises machine selection to minimise energy consumption.
Results at the Gorenje Orodjarna pilot:
- 21% electrical energy reduction per operation and 37% overall energy reduction;
- 22% scrap reduction across four representative components;
- 22% lower energy costs and 38% lower tool-wear costs;
- 13 data-driven machine-learning models and 2 optimisation tools for operators;
- 54% of energy-intensive machines monitored.
By combining manufacturing expertise with digital technologies, DENiM supports Gorenje Orodjarna's transition toward a smarter, more sustainable and energy-efficient toolmaking environment.
