The AI Advantage for Today’s Industrial Facility Managers

Employment in production occupations – such as food processing, power plant operations, and semiconductor manufacturing – is projected to decline over the next decade, despite the increasing demand for workers in these fields. Industrial facility owners and managers can address this widening employment gap by improving their industrial facilities to attract workers back, balancing productivity, cost, and workforce wellness.

AI and smart building technologies are emerging as essential tools for people-first facility management, which can be a key differentiator for manufacturers looking to recruit factory talent. Further, when facility managers utilize AI, particularly for advanced data analytics, they can significantly outpace traditional methods of maintenance and operations tracking and planning, allowing for greater overall efficiency and introducing valuable performance improvement opportunities. As with any new technology, understanding how to utilize AI tools for capturing and processing facility data effectively (to the benefit of both the workers and the business) is a must to fully leverage its benefits.

Wellness in the Industrial Environment
Industrial work is often regarded as one of the most labor-intensive and physically demanding sectors. That high level of activity might sound healthier than parking at a desk all day, but jobs that require standing for long periods, like factory work, have actually been associated with a double risk of incident heart disease compared to those where workers are sitting more. Work-related musculoskeletal disorders, chronic pain, and injuries can all take people out of the workforce for long periods, or even deter young workers from pursuing these careers. For owners facing external cost pressures (tariffs, onshoring and nearshoring, rising material prices, and automation), neglecting wellness ultimately has more detrimental long-term costs: absenteeism, turnover, and increasing insurance premiums.

Facility managers can leverage autonomous building systems to address factory environment conditions that contribute to worker wellness, health, and tenure, while competing with corporate jobs where these considerations have become leading amenities.

Air quality is one area where data-driven decision-making can have a substantial impact on workers. Air pollution is inflammatory to the human body, and is one of the key triggers for the gene behind chronic diseases such as diabetes, rheumatoid arthritis, depression, Alzheimer’s, and cancer. Improving indoor air quality (IAQ) by reducing CO₂ levels below 600 ppm helps sustain cognitive performance and limits productivity drops during extended work sessions. When CO₂ levels exceed 800 ppm, workers can feel tired and disengaged, increasing the risk of mistakes or injury. AI integration can help track these loads over time, pulling from occupancy sensors and MEP system data to introduce fresh air and improve conditions autonomously.

Occupancy patterns, tracked through both sensors and heat mapping, can also provide facility managers with important, real-time spatial utilization insights. Rather than relying on outdated metrics like cost per square foot, this data shows which zones and areas employees actually frequent the most, and which are underutilized. Through the addition of AI, the environmental conditions of these spaces can be optimized for IAQ and lighting, or even nudge employees to take breaks – helping facilities stay compliant with safety regulations and insurance requirements.

Operational Safety and Security Enhancements
Utilizing AI for anomaly detection and real-time monitoring also improves building security and identifies potential hazards promptly, ensuring a safe environment for all workers.​ AI-monitored cameras and building systems can identify equipment malfunctions, such as water or gas leaks, which can pose health risks and even lead to significant property or factory damage. This technology can also help detect adherence to safety protocols by monitoring compliance with regulations – for example, if workers are wearing the appropriate personal protective equipment (PPE) or entering unauthorized restricted areas – and generating detailed safety reports. These systems can also identify risks such as weapons or suspicious sounds, triggering an immediate emergency response, often before workers even recognize danger is near.

Translating this data into predictive analytics can help inform the layouts of workstations and material handling zones, as well as break schedules, to ensure the factory is as efficient as it is safe. This is key for facility managers seeking to support labor retention and avoid injuries.

Data protection is another area where AI can benefit facility managers. As factory operations are increasingly digitized, the potential for “leaks” of proprietary practices increases. AI-powered systems can monitor network traffic for signs of cyberattacks or breaches, helping to safeguard the company’s sensitive information.

Energy Optimization Benefits
Beyond the worker health and wellness benefits, AI integration can transform building operations by streamlining energy management. Energy efficiency is a key sustainability focus for facility managers, as 69.4 percent reported it’s their top sustainability priority. For facility managers whose landlords or owners are pushing this focus, as well, AI-driven analytics can evaluate energy consumption patterns, enabling modifications to systems such as HVAC and lighting that minimize energy waste and decrease utility costs.

Smart meters and sensors collect metrics such as air conditioning output, indoor temperature, and humidity; with AI integration, the system quickly flaps inconsistencies or unusual energy usage, which could indicate leaks, faulty wiring, or inefficient operations. Not only saving energy, but this also helps prevent costly failures. By tracking these metrics alongside occupancy and spatial utilization patterns, facility managers can minimize energy waste and reduce utility costs by incorporating AI into traditional workflows.

Maintenance That Thinks Ahead
A stable work environment – particularly when systems operate as expected – benefits current employees and also appeals to new talent who prioritize safety, consistency, and operational efficiency. For facility managers working with older factories, however, predictive and preventive maintenance can be a challenge. By analyzing sensor and mechanical system data, AI algorithms can quickly process data trends to predict equipment failures, minimize unexpected downtime, and create a less stressful factory culture, while extending the lifespan of important machinery and building infrastructure.

By aggregating and analyzing extensive datasets, autonomous building systems provide a safeguard to employee health by improving IAQ, identifying hazardous conditions, and ensuring environmental performance. These real-time insights enable smarter decisions around resource allocation, maintenance scheduling, and overall facility operations, reducing inefficiencies and supporting long-term cost savings for owners. AI helps to uncover inefficiencies that were previously hidden and implementing it may seem complex at first, but when facility managers start with small, clearly defined goals, they can yield immediate positive returns. The future lies in holistic facility oversight, where AI manages not just equipment lifecycles but also employee health and space performance.

Erin McDannald is a visionary entrepreneur, author, and innovator who operates at the intersection of biology, technology, and design. Her work explores how the built environment can evolve into a symbiotic system that nurtures both human health and the planet. As the CEO of Elevated, Erin has pioneered a smart building platform that transforms buildings into adaptive systems, integrating lighting, IoT, and analytics to create environments that are as responsive as they are sustainable. Her work challenges conventional notions of design and functionality, advocating for spaces that not only serve human needs but also work in concert with the Earth’s ecological rhythms.