Manufacturing plants run on energy, which means every inefficiency in a production line, a motor or a compressor shows up directly on the bottom line. As energy costs climb and environmental rules tighten, the ability to manage energy deliberately - not just consume it - has become a core operational skill, not an optional extra.

This Training Course from the Arab British Fellowship Training Academy equips manufacturing professionals to audit their own operations, apply proven efficiency measures on the production floor, bring in renewable energy where it makes sense, and build the kind of energy management system (EnMS) that keeps savings going rather than fading after year one.

What You'll Gain

• A clear understanding of how energy management principles apply specifically to manufacturing operations.
• The ability to audit a plant, map its energy use and set realistic savings baselines.
• Practical techniques for cutting energy use in production processes and industrial equipment.
• Knowledge of how to integrate renewable energy sources into manufacturing operations.
• Skills to build and run an energy management system aligned with ISO 50001.

Who Should Attend?

• Energy managers and engineers overseeing efficiency improvements in manufacturing facilities.
• Operations, facility and production managers looking to embed energy-saving practices into daily workflows.
• Sustainability coordinators and energy consultants working on corporate energy programmes.
• Manufacturing executives who want to understand the financial and operational case for energy management.

Module 1: Why Manufacturers Can't Ignore Energy Anymore

• The scale of energy use in manufacturing and which processes are the biggest consumers.
• The business case: cost savings, compliance and sustainability pressure all pointing the same way.
• Impact of unmanaged energy use on both operating costs and environmental footprint.

Module 2: Core Concepts and the ISO 50001 Framework

• Defining energy management and its role in manufacturing operations.
• Energy performance indicators (EPIs) and how benchmarks are set.
• An overview of ISO 50001 as the reference framework for energy management systems.

Module 3: Auditing the Plant - Method and Tools

• Steps involved in performing a manufacturing energy audit.
• Tools and software used to collect and analyse audit data.
• Identifying savings opportunities directly from audit findings.

Module 4: Mapping Usage and Setting Baselines

• Techniques for creating energy maps that visualise consumption across the facility.
• Establishing baseline energy use for meaningful performance comparison.
• Setting realistic consumption benchmarks and targets.

Module 5: Finding Savings on the Production Line

• Analysing energy consumption during production to spot improvement areas.
• Lean-manufacturing techniques and energy-efficient equipment upgrades.
• The role of automation in optimising energy use during production.

Module 6: Upgrading Industrial Equipment

• Maintenance and upgrade practices that reduce machinery energy consumption.
• Variable frequency drives (VFDs) and energy-efficient motors.
• Assessing energy use in lighting, HVAC and other supporting equipment.

Module 7: Recovering and Reusing Waste Energy

• Identifying heat-recovery and waste-heat-utilisation opportunities.
• Systems for recycling and reusing energy within the plant.
• The efficiency and cost impact of energy recovery.

Module 8: Bringing Renewables into the Plant

• Renewable options suited to manufacturing: solar, wind, biomass, geothermal.
• Technical and financial feasibility of adopting renewable systems.
• Regulatory incentives supporting renewable adoption, with real-world examples of solar integration.

Module 9: Building an Energy Management System

• Key components of an EnMS: policy, objectives, monitoring and review.
• Aligning the system with ISO 50001 and pursuing certification.
• Benefits of a formal EnMS versus ad-hoc efficiency efforts.

Module 10: Monitoring, KPIs and Continuous Improvement

• Using monitoring tools to track energy consumption in real time.
• Key performance indicators for measuring ongoing efficiency.
• Data analysis and reporting that supports continuous improvement.

Module 11: The Money and the Message - Costs, Financing and Reporting

• Calculating ROI and identifying low-cost or no-cost savings opportunities.
• Financing routes: government incentives, ESCOs, grants and tax credits.
• Reporting sustainability outcomes to stakeholders and aligning with corporate goals.