The global imperative to reduce industrial carbon emissions and improve energy efficiency has intensified demand for intelligent energy management solutions. Factory environments, characterized by complex and heterogeneous energy consumption patterns ...
The global imperative to reduce industrial carbon emissions and improve energy efficiency has intensified demand for intelligent energy management solutions. Factory environments, characterized by complex and heterogeneous energy consumption patterns across HVAC systems, industrial machinery, lighting, and production lines, represent one of the largest opportunities for energy optimization. This thesis presents the design, implementation, and evaluation of a Smart Energy Management System (SEMS) - a simulation-based platform that models factory energy profiles and employs machine learning techniques, specifically Random Forest (RF) Regression, Isolation Forest, and Random Forest, to generate actionable AI-powered ranked optimization suggestions. The system integrates a physics-grounded simulation engine that models eight device types - solar panels, wind turbines, batteries, HVAC units, lighting, EV chargers, appliances, and smart meters - driven by latitude-based weather and profile-aware occupancy models. The AI pipeline combines Random Forest (RF) Regression for multi-horizon load forecasting, a hybrid anomaly detector pairing four explicit rules with an Isolation Forest, a dual-model efficiency classifier (Random Forest for categorical labels and Random Forest (RF) for continuous scores), and a tariff-driven load-shift optimizer. Evaluation results demonstrate that the regression model achieves a mean absolute percentage error (MAPE) of 4.7% on a 30-day holdout dataset, the clustering module identifies three distinct energy waste patterns leading to average simulated savings of 18.3% per factory zone, The suggestion engine produces ranked, deduplicated recommendations with estimated savings in both kWh and cost. A usability evaluation using the System Usability Scale (SUS) places the dashboard in the above-average to excellent range. The thesis contributes a replicable simulation framework, a validated ML pipeline for energy management, and an open-source dashboard implementation to the sustainable computing research community.