Published: March 09, 2015  Updated: April 03, 2025

Beyond Maintenance: Unexpected Energy Savings with CMMS

In the relentless pursuit of cost reduction and enhanced operational efficiency, reliability professionals often overlook a substantial drain on resources: energy consumption. A Computerized Maintenance Management System (CMMS) offers more than just maintenance scheduling; it provides a powerful avenue for uncovering and mitigating hidden energy waste. Let's delve into the unexpected energy savings with a CMMS.

The Foundation: Preventative and Proactive Maintenance

Let's start by understanding reactive maintenance. At the core, this mindset has you tending to assets only when they fail or break down. As the referenced article shows, this has numerous problems. With that in mind, let's look at asset energy usage.

Much of energy efficiency lies in meticulous equipment maintenance. When machinery operates sub-optimally due to neglect, it demands more energy to perform its functions. Because of reactive maintenance, assets don't stay as reliable and may not return to full reliability after a repair.

A CMMS facilitates the scheduling and tracking of preventative and proactive maintenance, ensuring equipment runs at peak efficiency. This translates directly to reduced energy consumption. Think of a large industrial air compressor: a poorly maintained compressor with clogged filters and worn seals will require significantly more electricity to achieve the same output as a well-maintained unit. With a CMMS, you can ensure timely filter replacements and seal checks, avoiding this energy waste.

Another example: A manufacturing plant with numerous conveyor belts. If the bearings on these belts don't receive regular inspection and lubrication, they create increased friction, requiring more power to move. A CMMS can schedule regular lubrication and bearing checks, keeping energy usage down.

HVAC Systems: A Major Energy Consumer

HVAC systems represent a significant energy expenditure in any facility. A CMMS can be instrumental in managing these systems effectively. A clogged filter forces the system to work harder, consuming more energy. Imagine a large office building with dusty, old HVAC filters. The system must work harder and staff may not feel the full effects.

Like the above examples of scheduling, a CMMS can help a manager plan regular filter replacements, coil cleaning, and system tune-ups.

Addressing Airflow and Leakage

Airflow obstructions and leaks also contribute to energy waste. Once again, facility managers can add inspections to their preventive maintenance list. By generating a forecast of upcoming PMs, technicians can make sure vents and intakes stay clear of obstructions. By maintaining a record of inspections and repairs, a CMMS helps prevent energy losses due to blocked airflow.

Furthermore, you can schedule the sealing of windows and doors, reducing air leakage and improving insulation. An industrial freezer with a poor door seal will leak cold air, forcing the refrigeration system to work harder, and increasing energy use. A CMMS can schedule regular seal inspections and repairs, preventing this costly energy drain.

Energy audits provide excellent data for potential energy savings and help you focus improvements. Look at insulation, seals, and other areas for energy conservation. Make this a record in your CMMS PM list. Documentation within the system helps you look back on previous audits. Use this information to check the quality of the actions taken.

Discover how streamlined maintenance processes can elevate production. Learn more.

Lighting: Simple Changes, Significant Savings

Lighting presents a major area where a CMMS can drive energy savings. Implementing and tracking lighting schedules, ensuring lights are turned off in unoccupied areas, and using timers can significantly reduce energy consumption. The PMs could include regular bulb replacements. Work requests might cite flickering or inefficient bulbs. A manager can review the request and convert it to a regular work order. With prioritization settings, technicians know the importance of such jobs.

Think about the lighting in any facility. Not only do you have internal office/rooms, hallway, and stairwell lights, but you also have parking lot and security lighting, perhaps lights along walkways, exits, and backup emergency lighting. Remember to inspect and test these routinely. Maximizing natural light. This means inspections of windows, skylights, and automatic blinds and shades.

Education and Employee Engagement

Ultimately, companies need a team effort for energy efficiency is a team effort. A CMMS can play a role in educating employees about energy conservation practices and tracking energy-saving initiatives. By providing data and insights into energy consumption, a CMMS empowers employees to make informed decisions and contribute to energy savings. Setting realistic energy reduction goals and tracking progress within the CMMS encourages accountability and fosters a culture of energy conservation. Consider using a CMMS to track energy usage per department and create friendly competitions to see who can reduce the most. This fosters engagement and awareness.

Training sessions can educate employees about the importance of energy management and provide practical tips for reducing energy waste. Recognizing and rewarding employees for their contributions to energy savings reinforces positive behavior and motivates continued efforts.

For energy conservation, a CMMS comes in handy in so many ways. By using the various features for assets, inventory, and work order management, you can uncover hidden energy savings, reduce operational costs, and contribute to a more sustainable future. The system provides the tools to manage maintenance effectively, track energy consumption, and educate employees, ensuring that energy efficiency becomes an integral part of the organization's culture.

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