A Sustainable Maintenance Optimization: Enhancing Efficiency and Costs Reduction with SDG Goals

Objective: This research aims to enhance the sustainability and efficiency of industrial maintenance by reducing electrical system maintenance costs, aligning with the principles of SDG 9 and SDG 12. Given the necessity for the factory to optimize resource utilization and minimize unnecessary maintenance expenses, the researcher implemented condition-based maintenance (CBM) for low-voltage AC motors. Theoretical Framework: This approach eliminates non-value-added activities, reduces waste in maintenance operations, and transitions the traditional five-years major preventive maintenance plan to a more efficient, data-driven strategy. Method: By analyzing monthly mechanical inspections and three-years electrical inspections for abnormal signals, decisions were made to conduct major maintenance only when necessary. The methodology consists of three key processes: 1) Study the preventive maintenance process for low-voltage AC motors. 2) Analyze hidden inefficiencies and waste in the preventive maintenance process. 3) Implement the condition-based maintenance technique to optimize maintenance efficiency and sustainability. Results and Discussion: The data-driven methodology significantly enhanced resource efficiency, reducing maintenance costs for low-voltage AC by achieving a 55.1% cost reduction. This paper contributes to sustainable industrial practices by optimizing energy and maintenance resource utilization. Research Implications: This paper presents to reducing unnecessary maintenance, preventing the waste of resources, labor, and energy while ensuring production reliability. Including a framework for predictive and condition-based maintenance, which can be adapted to other industrial equipment beyond AC motors. Encouraging the adoption of smart maintenance technologies, such as real-time condition monitoring, for improving energy efficiency and system reliability. Originality/Value: This paper highlights the strategic benefits of applying condition-based maintenance (CBM) to low-voltage AC motors, offering significant implications for sustainable industrial operations, cost efficiency, and maintenance optimization.