Reducing Energy Waste & Downtime: A Smarter Approach to Manufacturing Maintenance
SOUTHEAST Session: Manufacturers face a dual challenge: reducing unplanned downtime while also addressing rising energy costs and sustainability targets. Traditional Reliability-Centered Maintenance (RCM) has focused on asset reliability and uptime, but it often overlooks the significant energy wasted when machines operate in a fault state, up to 20% more electricity. This presentation introduces Energy-Centered Maintenance (ECM) , a next-generation approach that combines predictive maintenance with energy efficiency. By monitoring key parameters of rotating equipment, ECM helps manufacturers detect early signs of inefficiency, prevent failures, and reduce greenhouse gas emissions. Attendees will see real-world case studies, including how a pharmaceutical manufacturer deployed over 140 sensors across global facilities to save 136 hours of downtime and $42,000 in excess energy usage. The session will demonstrate how ECM strategies deliver measurable ROI, improve operational excellence, and align maintenance practices with corporate sustainability goals