Power quality: a blind spot directly affecting production efficiency

Schneider Electric shares solutions for effective energy management at the Innovation Talk event. In manufacturing increasingly dependent on power electronics, automation, and sensitive production lines, power quality (Power Quality – PQ) is becoming a foundational factor that directly affects the performance and reliability of the entire system. The gap between 'electricity consumed' and 'electricity used efficiently.' Most enterprises today manage energy based on electricity consumption. However, this approach does not fully reflect the efficiency of electricity use in practice. Studies in the field of power quality show distortions such as harmonic distortion can increase losses in the system, cause equipment overheating, raise current, and reduce operational efficiency. This means the system must consume more electricity to maintain the same production level. According to data shared by Schneider Electric at Innovation Talk on solutions for energy-efficient and sustainable use of power systems, in some cases power quality issues can cause energy consumption to rise significantly. Mr. Pavel Rvachev, Head of Services of Schneider Electric Vietnam and Cambodia, spoke at the Innovation Talk. If in the early stage poor power quality primarily reduces energy-use efficiency, in the long term it directly affects equipment reliability and the entire production line. Among power quality issues, voltage sag is reported as one of the most common phenomena in industrial electrical systems and is the main cause of equipment disruption. Studies show voltage fluctuations can lead to operational deviations, machine stoppages, or reduced equipment life due to overheating and electrical stress. The impact level can vary by industry and system specifics. According to Schneider Electric, in some cases sag can significantly increase the rate of equipment failure. Some academic studies, including analyses in Frontiers in Energy Research, also report a link between voltage instability and increased equipment faults in industrial systems, with reports in some cases up to about 20%. Not only does it affect equipment, power quality directly affects production efficiency. According to Empower IT, in the food processing sector, voltage fluctuations caused by poor power quality can raise energy costs by about 10% and simultaneously reduce production output by about 5%. Notably, these effects often do not occur immediately, but accumulate over time, making it difficult for companies to identify causes if they only address individual incidents. From incident response to system governance: End-to-end approaches to power quality. According to Mr. Pavel Rvachev, Schneider Electric Vietnam and Cambodia’s Head of Services, an effective approach to power quality should start with accurate on-site measurement and diagnosis before implementing suitable solutions and establishing continuous monitoring. You cannot optimize something you do not understand, you need the right data, he emphasized. First is surveying and measuring to identify issues such as voltage sag or harmonics. This is not only a technical step but a prerequisite for a company to correctly identify the issue and make optimized decisions based on data. Next is applying technical solutions appropriate to each system, such as voltage restoration devices, harmonic filters, or reactive power compensation solutions. Finally, continuous monitoring via digital platforms allows real-time monitoring of power quality and early detection of abnormalities. What sets this deployment model apart is its shift from reactive to preventive. Instead of only addressing issues when incidents occur, enterprises can proactively manage risk and optimize operations based on data. According to experts, power quality is inherently a part of energy efficiency, and thus directly affects the ability to implement energy-saving strategies as well as the Net Zero roadmap for the enterprise. In a broader context, power quality is not only about energy efficiency but also becomes a foundation for ensuring production stability and implementing sustainable development goals in the long term. When the electrical system operates stably and optimally, companies not only reduce losses but also build a foundation to implement energy-saving strategies and pursue long-term competitiveness. As energy costs rise and requirements for production stability grow, power quality is increasingly being re-evaluated, no longer just a technical parameter of the electrical system. Instead, this is a factor that directly affects operational efficiency, equipment reliability, and cost control for the business. As production lines depend more on stable electricity, investing in power quality becomes not only about reducing risk but also a part of a strategy to optimize energy use and enhance competitive capability in the long run.