Smart Tech in Facility Management for Manufacturers
Facility leaders today face a dual challenge: keeping production running smoothly while preparing for future disruptions. Technology isn’t just about modernization—it’s about minimizing risk, maximizing uptime, and making better decisions. In fact, unplanned downtime is widely recognized as a major cost driver in manufacturing—estimates have placed the figure in the tens of billions annually. Many incidents are tied to equipment failures that better monitoring and maintenance practices could help prevent.
In this blog, we’ll explore how manufacturers are using technology to strengthen facility management.
1. Predictive Maintenance: Reducing Downtime Before It Happens
Predictive maintenance tools use IoT sensors and data analytics to monitor equipment health in real time. This allows teams to catch potential failures before they cause production delays.
Deloitte and others have reported that predictive maintenance can significantly reduce both unplanned downtime and maintenance costs (Deloitte Smart Factory Report). For example, Siemens has highlighted improvements in uptime through these systems, including work at its Regensburg facility.
Across the industry, predictive maintenance is gaining traction as a practical solution for improving equipment reliability and resource allocation.
2. Smart Energy Management: Cutting Waste and Cost
The U.S. Energy Information Administration (EIA) reports that the industrial sector consumes a large share of total U.S. energy—more than 30% in many years (EIA Industry Energy Use). This creates substantial opportunities for savings.
Technologies like automated HVAC systems, real-time energy monitoring, and load balancing tools help facilities reduce both consumption and emissions. In one case, Schneider Electric reported a 10% reduction in process energy usage at intensive sites through its EcoStruxure system (Schneider Electric Case Study).
Smart energy management helps manufacturers identify under-monitored areas and optimize usage without sacrificing output.
3. Integrated IT/OT Systems: Seeing the Whole Picture
Manufacturers often rely on separate systems to manage IT functions (like MES) and OT components (like machinery and sensors). Integrating these systems creates a unified operational view.
Industry leaders, including Rockwell Automation, have emphasized the potential benefits of IT/OT integration, such as improved operational visibility and responsiveness (Rockwell Automation Blog). While public case studies remain limited, several manufacturers have explored integrated strategies to align their IT and OT systems in pursuit of greater efficiency.bé
To maintain the trustworthiness of insights like these, we focus on citing credible sources and avoid including specific collaborations or outcomes that cannot be substantiated with publicly available information.
When IT and OT are aligned, teams gain quicker insights, greater consistency in performance tracking, and stronger responsiveness across multiple sites.
4. Facility Security: More Than Just Locked Doors
As facilities digitize, both physical and cybersecurity become critical. Modern access control systems (ACS) and video monitoring systems (VMS) help secure assets, monitor movement, and support compliance.
According to MarketsandMarkets, the global access control market is projected to grow from $10.4 billion in 2024 to $15.2 billion by 2029, with manufacturing expected to remain a key segment driving this demand. These systems—using biometrics, keycards, and real-time alerts—are becoming integral to plant safety protocols.
Security systems that integrate with facility management platforms can increase visibility and accountability with minimal operational disruption.
5. Data-Driven Decision Making
Data is central to modern facility management. While estimates vary, surveys consistently show that more manufacturers are using analytics tools to guide decision-making on maintenance, energy, and staffing.
Dashboards, AI, and cloud-based platforms are making it easier to interpret operational data. For instance, real estate and facility management firms like CBRE emphasize how usage-based data and analytics can play a critical role in improving operational efficiency and planning (CBRE Insights).
With the right tools in place, manufacturers can uncover patterns, address inefficiencies, and plan proactively.
Final Thoughts
Explore our Facility Optimization Services to assess where technology can make the biggest difference in your plant.
Facility management is no longer just about maintenance—it’s a strategic function. The technologies outlined above are helping manufacturers strengthen operations, reduce risk, and gain clarity across systems.
If you're considering where to start, begin by evaluating your visibility into areas like energy consumption, equipment performance, and access control. Are your systems working in sync? Are your decisions backed by real-time data?
Even incremental changes—like connecting maintenance logs with equipment data or streamlining access protocols—can improve outcomes. The key is identifying the tools that fit your facility’s needs and goals.
We're always learning from the field and are glad to share what others in the industry are doing well.
Have you read?
Top Facility Management Issues in Manufacturing
5 common mistakes in Industrial Preventive Maintenance
Discover how effective MRO practices can enhance efficiency
Choosing the Right Facility Management Partner for Your Industrial Plant
