Fiberon Decking Saves $274K with AI Predictive Maintenance Across 16 Facilities

Fiberon Decking, a leading manufacturer of composite decking and railing products and a business of Fortune Brands Innovations, has transformed its manufacturing operations through AI-powered predictive maintenance deployed in partnership with Augury. The deployment centers on Fiberon's flagship facility in New London, North Carolina, where an 8-month pilot began in December 2023. Augury's AI platform continuously captures over 10,000 machine-health signals per month from vibration, temperature, and current sensors attached to critical production equipment including extruders, mixers, melt pumps, and material handling systems. Key results from the pilot: - $274,000 total cost savings over 8 months - 178 hours of unplanned downtime avoided - 2.5x return on investment - 96% AI alert response rate from maintenance teams - One specific intervention on a L20 Melt Pump saved $56,000 by catching bearing degradation weeks before failure Ric Wojcik, Senior Manufacturing Engineering Manager at Fiberon, noted that the AI caught degradation patterns their previous vibration analysis missed, enabling proactive parts ordering and scheduling. Following the pilot's success, Fiberon has expanded the Augury deployment to over 1,000 machines across 16 facilities in three countries (United States, United Kingdom, and Mexico), establishing a new standard for machine-health excellence in the building materials industry.