5 Signs Your Factory Needs Monitoring
In the modern age of technology, data, and net-zero goals, most business owners have at least heard of smart monitoring or remote monitoring solutions. But how do you know if it’s right for you and your factory?
In this article, we’ll explore five clear signs your factory needs monitoring and why it’s essential for operational success.
– High Energy Costs
Energy costs are a major burden for many businesses, especially in energy-intensive industries. In fact, according to the UK government, energy typically accounts for 15–20% of total manufacturing costs. But do you really know where your energy is going?
How Monitoring Helps:
Remote monitoring lets you track real-time electricity, water, and gas usage, along with costs, kWh/Litres Per Hour, and associated emissions. By establishing clear usage trends, you can spot energy drains such as lights or equipment left on overnight, taps running, or unnecessary heating.
Fun Fact:
Studies show that simply identifying and correcting unnecessary energy consumption can cut energy bills by 10–20%, a substantial saving for any business.
Further, machine-level monitoring reveals your biggest energy users, verifying which assets are truly “energy hungry” and highlighting where efficiency improvements will have the biggest impact.
– Unexpected Downtime
A factory with multiple machines inevitably faces unexpected breakdowns, which halt production and cost money. Often, the cause of downtime isn’t immediately clear.
How Monitoring Helps:
Solutions like our SENTINEL package monitor electrical current, vibration, and temperature. They establish baseline data and automatically alert you when something deviates, such as rising vibration or abnormal electrical current, so you can intervene early.
Industry Insight:
The average cost of unplanned downtime in manufacturing can be as high as £180,000 per hour (source: Aberdeen Group). Monitoring helps you avoid these costs by predicting and preventing issues.
– Compliance
Many industries, including food, pharmaceuticals, and electronics, have strict environmental and operational compliance requirements. These might include temperature, humidity, air quality, and energy use reporting.
How Monitoring Helps:
Remote monitoring solutions give you instant access to detailed environmental data, making it easier to stay compliant with regulations like ISO 50001 (Energy Management) or environmental standards from the Environment Agency. This not only reduces your legal risks but also demonstrates your commitment to sustainability and good practice.
– Storage Quality Issues
Storage conditions can make or break your product quality, especially for sensitive materials.
Examples:
- Wood and humidity: High humidity (>70%) can warp wooden materials, leading to defects in finished products.
- Carbon fibre storage: Some carbon fibre resins must be stored below -18°C to prevent degradation.
- Food & beverage: UK food safety laws require cold storage to stay below 8°C to prevent bacterial growth.
How Monitoring Helps:
Monitoring temperature and humidity in storage areas ensures ideal conditions are always maintained. Automated alerts can trigger responses, like adjusting HVAC or switching on dehumidifiers, before quality issues or spoilage arise.
– Increase in Staff Sickness
While some staff sickness is unavoidable, poor workplace conditions can directly contribute to higher illness rates and lost productivity.
Key Environmental Factors:
✅ Air Quality: Manufacturing can release particulates (PM1, PM2.5) that cause respiratory and cardiovascular issues.
✅ NOx and VOCs: Toxic, explosive, or flammable gases (like nitrogen oxides and volatile organic compounds) can trigger headaches, dizziness, or long-term health issues.
✅ Temperature & Humidity:
- Ideal temperature for comfort & productivity: 16–20°C
- Ideal humidity: 40–60%
✅ CO₂ Levels: Above 900 ppm, CO₂ causes fatigue, headaches, and concentration problems.
✅ Sound: Prolonged exposure to over 80 dB can damage hearing and affect focus.
✅ Light: Poor lighting can strain eyes and reduce concentration. Using natural light where possible reduces energy use and supports health.
How Monitoring Helps:
Remote monitoring tracks air quality, humidity, temperature, CO₂, sound, and lighting in real-time, enabling quick adjustments to improve health and productivity.
Summary: Why Monitoring is a Smart Investment
✔ Reduce Costs
Energy, downtime, and environmental inefficiencies all drain profits. Monitoring uncovers these hidden costs and provides actionable data.
✔ Improve Reliability
Predictive insights catch problems early, keeping your factory running smoothly.
✔ Meet Compliance
Automatically generate data to prove regulatory compliance and support certifications.
✔ Enhance Productivity & Well-being
Create a healthier, safer environment for your team, boosting morale and output.
✔ Future-Proof Your Factory
With net-zero targets and tightening environmental standards, monitoring ensures you’re ready for tomorrow’s demands.
