AI: Your Manufacturing Energy Hero

AI to the rescue

Today’s modern technology allows us to monitor and track everything from the machines and people on the factory floor to HVAC and lighting systems. The challenge is that all that tracking and monitoring creates mountains of data that no human could ever sort through — certainly not fast enough to make any of it useful.

This is where AI comes in. AI can analyze all the data from your factory, plus historical and forecasted data on things like utility prices, the weather, and even world events in real-time. As a result, you can make informed decisions based on actual up-to-the-minute data on a host of operational issues, including your operation’s use of energy.

Applying AI in manufacturing

Here are a few examples of how AI can be put to good use in manufacturing facilities.

Energy analysis. The Energy INsights program in Indiana aims to use AI and data analytics to help small- and medium-sized manufacturers reduce their energy consumption and energy costs. Floor sensors collect data on assembly lines, machines, shifts, operator usage patterns, and more. AI analyzes the data in real-time to provide insights on participant energy use on a digital dashboard. The project is a collaboration between Indiana, Purdue and Notre Dame universities, the Emerging Manufacturing Collaboration Center, as well as corporate partners.

Smarter lighting You’ve probably heard about high-efficiency LED lighting, but smart LEDs take things a step further by integrating the power of AI. AI programs can suggest and manage automated lighting schedules based on data from occupancy sensors and typical room use. This means that if people are only using a portion of a large warehouse, for example, the AI will only turn on the lights in that section.

Maintenance schedules. Equipment that’s well-maintained is more energy efficient, has a longer life, reduces downtime, and lowers overall maintenance costs. AI can help you establish predictive maintenance schedules and alert you to potential issues. By analyzing actual usage data (like motor speeds, fan speeds, how the operator uses the piece of equipment, and other environmental considerations), you’ll be able to fix problems before they lead to significant downtime. You’ll also extend the life of your equipment.

AI is a powerful tool that can help manufacturers increase energy efficiencies, reduce operating costs and improve equipment performance.