IT in Manufacturing


AI-powered maintenance in future-ready data centres

January 2026 IT in Manufacturing

The data centre marketplace is facing a conundrum of sorts; on the one hand, operators are now investing heavily in infrastructure to meet AI’s growing demands, on the other hand, it still often relies on outdated maintenance methods to manage mission-critical equipment.

But with rising energy demands, talent shortages, stricter sustainability regulations and mounting risks of downtime, change has become non-negotiable. Enter Condition-Based Maintenance (CBM), which is powered by AI and is fast becoming a necessity in ensuring both competitiveness and resilience.


Canninah Dladla, cluster president for English-speaking Africa at Schneider Electric.

Why traditional maintenance falls short

There’s no doubt that time-based or reactive maintenance models have the potential to expose data centres to unnecessary downtime, inefficient resource use, higher costs and compliance risks.

Additionally, as AI workloads continue to drive demand for greater computational power and more complex infrastructure, failures in innovative technologies become costly. This is particularly true in sectors such as finance, healthcare and e-commerce, where outages can cause severe reputational damage and financial loss.

According to Uptime Institute, the average cost of IT downtime ranges from $6000 to $9000 per minute, with some outages exceeding $1 million. Talent shortages amplify the risk: more than half of operators (51%) reported difficulty in finding qualified candidates to fill job openings, for the third year running. In addition, Uptime Institute estimates that human error plays a role in more than 66% of data centre outages.

Traditional maintenance typically suffers from three flaws:

• Calendar-based servicing wastes resources and fails to prevent unexpected failures.

• Contracts often cover only narrow equipment sets, not entire systems.

• Technicians may lack the skills or connectivity to manage multi-vendor, multi-site ecosystems.

The solution: systemic CBM

AI-driven CBM offers a rounded and proactive solution. For example, by embedding sensors to collect real-time data on temperature, vibration, pressure and wear, CBM continuously monitors equipment health. Predictive analytics then identify issues before they escalate, enabling interventions only when necessary.

This approach reduces downtime, minimises human error and extends asset lifespans. Over time, CBM systems self-optimise by learning from new data points, creating a cycle of continuous improvement.

Importantly, human judgement remains vital to complement AI insights, ensuring multi-layered decisions in complex environments. CBM offers measurable benefits such as:

Efficiency and uptime: Predictive analytics reduce costs and downtime by 20% according to the International Energy Agency.

Resource optimisation: According to a recent Schneider Electric report, early CBM implementation can result in up to a 40% reduction in on-site maintenance interventions, and a 20% decrease in operational costs.

Sustainability: CBM reduces energy waste and extends equipment lifespans, directly supporting carbon reduction targets.

Reliability: Consistent performance and service continuity are maintained, even amid technician shortages.

Cybersecurity: Continuous monitoring identifies anomalies early, reducing vulnerabilities and centralising infrastructure management to shrink attack surfaces.

Cost reduction: Compass Data Centres cut costs through AI-powered maintenance, with a shift to CBM leading to a 40% reduction in manual, on-site interventions and a 20% decrease in OPEX.

A strategic imperative

Future-ready data centres demand proactive strategies. Whether designing a new facility or upgrading legacy systems, integrating AI-powered CBM is critical.

For new builds, embedding CBM from the design stage ensures seamless, data-driven operations from day one. For existing facilities, a phased rollout helps mitigate risks while transitioning infrastructure.

With CBM, data centres can evolve into efficient, resilient and sustainable facilities, ready to harness AI to optimise operations and drive innovation in an increasingly demanding digital world.


Credit(s)



Share this article:
Share via emailShare via LinkedInPrint this page

Further reading:

Install and commissioning time cut by 50% thanks to digital twin insights
Rockwell Automation IT in Manufacturing
ECM Technologies, a world leader in the design and manufacture of innovative and modular low-pressure carburising industrial furnaces, has developed a solution that removes many of the installation and commissioning challenges relating to the development, testing and deployment of large-scale heat treatment plants.

Read more...
Centralised control rooms where growth is elastic, not physical
Schneider Electric South Africa PLCs, DCSs & Controllers
Modernised control rooms feature distributed control system architecture consolidated into centralised compute environments. replacing traditional PCs with thin clients.

Read more...
Real-time monitoring and predictive maintenance in African data centres
ACTOM Electrical Machines IT in Manufacturing
Running a data centre in Africa brings many challenges. Traditional maintenance strategies struggle to keep up with these realities. Predictive maintenance offers a different approach.

Read more...
How smart signalling can transform Africa’s manufacturing future
Schneider Electric South Africa Industrial Wireless
Imagine a factory floor where humans and machines communicate in real time with issues flagged instantly, workflows adjusted seamlessly and downtime reduced to near zero. This is the reality unfolding across Africa as manufacturers embrace the next generation of intelligent signalling technologies.

Read more...
Unpacking the technoeconomic case for cleaner power in wastewater plants
Schneider Electric South Africa Electrical Power & Protection
Behind every reliable wastewater plant is an electrical system exposed to the effects of harmonics, voltage distortion and overloaded networks caused by fleets of variable speed drives on pumps and aerators.Together, they steadily drive up maintenance demands and elevate the risk of failure.

Read more...
Advanced DCSs preserve what must not change while enabling
Schneider Electric South Africa PLCs, DCSs & Controllers
Next-generation DCSs, such as Schneider Electric’s Foxboro, are preserving the best of the old while introducing the new in a less disruptive manner.

Read more...
Rethinking power for Africa’s data centres
Schneider Electric South Africa Electrical Power & Protection
Africa’s digital economy is scaling faster than its power systems. If it wants resilient, competitive and sustainable data centres, the starting point must be a grid-to-chip architecture rather than a genset-first mentality.

Read more...
Siemens ecosystem strengthens data and AI integration
Siemens South Africa IT in Manufacturing
Siemens has announced significant expansions to its Industrial Edge ecosystem, accelerating data and AI integration and releasing enhanced cybersecurity functionalities. These enable a seamless integration of IT and OT environments, optimise processes and reduce operational disruptions.

Read more...
Unifying building information into a sea of insight
Schneider Electric South Africa Electrical Power & Protection
Facility managers realise that in order to gain the most from building automation, they can longer deploy and operate technologies in isolation. Modern, integrated building management solutions address this challenge by bringing data from multiple sources and dispersed locations like HVAC, lighting, access control, lifts, generators, field devices, energy and

Read more...
Why digital LV switchboards matter
Schneider Electric South Africa Electrical Power & Protection
Today’s buildings account for up to 40% of global energy consumption and CO2 emissions. However, buildings are also expected to deliver higher availability and stronger safety performance while also being sustainable. Digital swirchboards make a difference in the way buildings are developed, upgraded and managed.

Read more...









While every effort has been made to ensure the accuracy of the information contained herein, the publisher and its agents cannot be held responsible for any errors contained, or any loss incurred as a result. Articles published do not necessarily reflect the views of the publishers. The editor reserves the right to alter or cut copy. Articles submitted are deemed to have been cleared for publication. Advertisements and company contact details are published as provided by the advertiser. Technews Publishing (Pty) Ltd cannot be held responsible for the accuracy or veracity of supplied material.




© Technews Publishing (Pty) Ltd | All Rights Reserved