Integrated Control of Battery Storage and Switch-Off Policies for Energy-Efficient Manufacturing Systems

Escalating energy costs and peak power demand charges pose significant challenges to the manufacturing sector. In response, industries are increasingly adopting on-site renewable energy sources and Battery Energy Storage Systems (BESSs). However, maximizing their economic benefit requires sophisticated control strategies that integrate energy management with production operations. This paper proposes and evaluates an integrated and adaptive rule-based coordination framework for BESS and machine-level switch-off policies in a production environment. Using discrete-event simulation, we model a four-machine manufacturing flow line powered by the grid and an on-site solar PV plant. We compare six distinct control policies, ranging from a benchmark case without storage to progressively more integrated context-aware strategies that incorporate price-aware BESS charging, dynamic peak-shaving, and adaptive machine switch-offs. The results demonstrate that integrated policies yield substantial economic benefits. The most advanced policy dynamically coordinates BESS dispatch with machine-level switch-off decisions based on electricity prices, production conditions, and energy availability, achieving the largest reduction in total energy costs and peak grid demand among the evaluated policies. This study quantifies the synergistic effects of combining supply-side (BESS) and demand-side (switch-off) strategies, providing a framework for developing resilient and cost-effective energy management systems in modern manufacturing.