With TRACTIAN Technologies, Johnson Controls Generated Over $2.6M in Savings

Challenge

Johnson Controls operates one of the world’s largest catalogs of HVAC and building control systems. Their equipment powers everything from schools and hospitals to factories and plants around the globe.

But with thousands of assets running daily across complex environments, visibility was limited:

• Condition monitoring was outsourced and low-frequency, leaving gaps in asset health data
• Power inefficiencies were contributing to excessive operational costs
• The team lacked a unified strategy for transitioning to Condition-Based Maintenance (CbM) at scale

Without the right tools, they couldn’t act early—and small maintenance gaps often grew into costly issues.

Solution

To gain better control and move toward a predictive approach, Johnson Controls deployed Tractian vibration sensors and AI-powered condition monitoring across multiple sites.

With this system, the maintenance team now gets real-time insights into equipment conditions—without needing manual inspections or outside consultants.

Key capabilities include:

• Live vibration and temperature monitoring across critical assets
• Real-time energy tracking to reduce consumption inefficiencies
• AI diagnostics that flag issues and recommend actions before failures happen

“We want to be world-class at manufacturing—and we can’t do that without a predictive maintenance solution.”

Luis Moncada

Maintenance Manager

Impact

Tractian enabled Johnson Controls to shift from reactive to proactive maintenance—improving reliability, cutting downtime, and helping justify further expansion of condition monitoring across the company.

In less than 12 months, they achieved:

• $2.6M in total savings across monitored facilities
• 31M+ sensor data samples processed into actionable insights
• Increased reliability across sites, with MTBF (Mean Time Between Failures) climbing to 62 days and average MTTR (Mean Time to Repair) dropping to 12.4 hours

These improvements were driven not only by better failure detection, but also by the strategic use of Tractian platform to streamline alignment checks, lubrication routines, and asset-specific tuning.

“I believe the future is highly personalized, with AI at the center. I want alerts based on my utilization, my equipment, and my way of stressing machines. Tractian is simply more agile in applying new technologies—and more collaborative when it comes to ideas and innovation.”

Luis Moncada

Maintenance Manager

What's Next

With measurable wins across uptime, efficiency, and cost savings, Johnson Controls continues to expand its use of Tractian’s condition monitoring platform.

The goal: a company-wide standard for predictive maintenance that’s smarter, more adaptable, and built around the realities of modern industrial operations.