Sustainability is much more than a buzzword or a trend — it’s a fundamental force that’s reshaping countless industries. As more and more consumers become concerned about the impact they have on the environment, they’re seeking out products and services from companies that are trying to reduce their ecological footprint. Whether it’s the use of recyclable or biodegradable materials, implementing efficient equipment that consumes less energy, adopting renewable power sources and/or other methods, companies that can demonstrate a commitment to sustainable operations are positioned to take advantage of evolving consumer behavior.
In particular, manufacturers are finding the shift toward sustainability aligns in many ways with the efforts they’re already making. Even before “green” became more than a color in the public consciousness, manufacturing operations were always looking out for ways to make their facilities and processes more efficient. Cutting down on energy consumption, streamlining operations and using fewer resources isn’t just good for the planet — it’s also good for the bottom line.
In this context, it isn’t hard to see how a strong and well-organized preventive maintenance protocol helps manufacturers meet their sustainability goals. Keeping machinery and infrastructure in optimal condition is critical for reducing waste and improving efficiency, which are core elements of becoming an eco-friendlier operation. However, that isn’t to say that simply embracing the tenets of preventive maintenance makes a manufacturer more sustainable. There are many ways a manufacturing maintenance team can adjust its approach to be more ecologically sound, and it’s important to understand these if companies want to enhance the value they offer their customers.
The role of maintenance in a sustainable operation
Simply put, neglecting maintenance hurts a production facility from a sustainability perspective. Equipment that isn’t kept in prime working order can experience drops in efficiency due to worn components, blocked filters, leaking connections and other issues. All of this means machinery consumes more energy than it needs to, which results in wastednatural resources. Inefficient equipment also may contribute to higher emissions of greenhouse gases that have a negative effect on the environment.
That’s to say nothing of the ecological impact of equipment that breaks down entirely due to lack of proper care. Any unexpected shutdowns in a manufacturing facility can result in an inordinate amount of waste as teams scramble to get the equipment back online as quickly as possible. Without the right attention before shutdowns occur, teams consume more resources than if they performed preventive work in the first place. With well-maintained machinery, manufacturing plants operate at peak efficiency, which helps them meet their sustainability targets.
Sustainable maintenance strategies in action
There are many different strategies manufacturers can employ to enhance the effect their maintenance teams have on their overall ecological footprint. Some of the most important of these include:
Preventive maintenance to eliminate waste
Preventive maintenance is focused on keeping equipment online for as long as possible and preventing unexpected shutdowns. This means replacing worn parts and other tasks to improve the overall health of the equipment before failures have a chance to occur. Not only does this prevent unnecessary part replacements and extend the lifespan of assets, but it also reduces energy surges caused by malfunctioning equipment. Crews also need to order fewer replacement parts, which reduces emissions created by logistics.
Lubrication and fluid management
It may seem like a simple thing, but just keeping equipment lubricated as intended can have a significant effect on a manufacturer’s sustainability efforts. Components that are properly lubricated function far more efficiently, helping to cut down on energy consumption and the associated emissions. At the same time, it also reduces wear on parts that can lead to shutdowns or excessive use of replacements. However, it’s important to pair this strategy with a stringent program for industrial fluid management. This ensures potentially hazardous materials such as motor oil and coolants are handled as carefully as possible to prevent spillage and contamination.
Equipment lifecycle optimization
Knowing when to repair equipment and when to replace it is essential for reducing waste. Partnering with industrial maintenance experts can help manufacturers adopt circular economy strategies that encourage them to reuse, refurbish and recycle asset components when appropriate in lieu of replacing them. Being careful with this approach can help prevent unnecessary purchases of parts and make maintenance more efficient.
Leveraging IIoT for sustainable maintenance
One of the most effective tools industrial maintenance teams have at their disposal today is the Industrial Internet of Things (IIoT). This equips machinery with an array of sensors that detect environmental conditions, operation speed and other metrics that are all fed into a single platform for analysis. Maintenance professionals can gain real-time insights into the health and performance of equipment, which informs their efforts to schedule maintenance tasks. Armed with this information, they can prioritize work that would have the biggest impact on preventing downtime or inefficiency. With IIoT sensors and software, manufacturers also can integrate the data into their enterprise platforms to simplify ESG reporting for compliance and audits.
Sustainable spare parts & inventory management
Another area that can have an effect on a manufacturer’s sustainability efforts is inventory management. MRO organizations are always trying to find the optimal balance between the demand for spare parts and the inventory they keep on hand. Today, MRO professionals have a new tool to help them in the form of artificial intelligence algorithms. Software with AI built in can analyze usage patterns and equipment health informed by IIoT sensors to optimize stock levels. MROs can predict with greater accuracy how many parts they will need in the foreseeable future, which prevents the expiration of parts and reduces the logistics needed for deliveries. By reducing the footprint created by excess inventory through predictive just-in-time stocking, MROs can ensure they have the most efficient and sustainable operations possible.
Benefits of sustainable maintenance programs
With a program focused on sustainability, manufacturers can enhance their maintenance operations in a number of ways. Some of the most impactful benefits they can experience include:
- Reduced operating costs: Many of the goals of sustainability overlap with manufacturers’ desires to streamline their operations and save money. Preventing unexpected outages, reducing energy consumption and eliminating waste do more than improve a company’s environmental footprint — they also lead to significant cost savings and lower overhead that improves profit margins.
- Extended equipment life: By focusing on preventive maintenance, manufacturers can keep their most valuable assets online for as long as possible. This adds up over time to fewer resources devoted to costly emergency repairs and reduced industrial waste that could end up in landfills.
- Higher investor confidence: Being able to demonstrate a commitment to ESG can be a powerful motivator for many investors. As more decisions are influenced by a company’s sense of responsibility in addition to its profitability, manufacturers that clearly demonstrate their commitment to sustainability gain a competitive edge over those who do not.
- Better compliance: Meeting regulatory requirements with regard to ecological concerns becomes much easier and more effective when manufacturers align their maintenance operations with sustainability. This means there’s less risk of being sanctioned for noncompliance and less red tape to worry about during audits.
- Competitive advantages: Consumers today are savvier about the products they buy, and in many cases, they will choose the manufacturer who demonstrates the greater commitment to sustainability. By making their entire operations from top to bottom greener, manufacturers can gain an edge over their competitors.
How outsourced maintenance supports sustainability goals
With sustainable maintenance made up of so many moving parts, it can be challenging for a manufacturer operating at any scale to implement it entirely in-house. This is why so many sustainable manufacturing operations turn to outsourced maintenance providers to deliver managed services.
These outsourced providers offer a wide range of services that align with sustainability initiatives, including predictive maintenance, IIoT-enabled solutions, remote asset monitoring and MRO supply chain optimization. The experts these providers employ can work closely with manufacturers to ensure they have all the expertise and resources they need to streamline their operations and implement best practices with regard to sustainable maintenance.
Taking the next step toward sustainability
Manufacturers looking to maximize the benefits of a sustainable maintenance program should begin with a comprehensive audit of their current maintenance and energy usage practices. This will give them a better understanding of where they are performing well and where they need some improvement.
Beyond that, perhaps the best way to implement change is to partner with an experienced maintenance provider like ATS. We offer numerous capabilities to support green manufacturing, including predictive maintenance, digital transformation and supply chain alignment. Working with the experts at ATS provides manufacturers with the knowledge and services they need for reducing waste and improving the overall sustainability of their maintenance programs. To learn more about how ATS can deliver sustainable maintenance that makes a difference, reach out and speak with one of our representatives today.
