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To reduce energy consumption for sustainable and energy-efficient manufacturing, continuous energy monitoring and process tracking of industrial machines are essential. In this paper, we introduce a novel approach to reduce the number of required sensors in process tracking by identifying the operational states based on real-time energy data. Finite-state machines are used to model the engineering processes, and a two-stage framework for online classification of real-time energy measurement data in terms of machine operational states is proposed for energy audit and machine scheduling. The first stage uses advanced signal processing techniques to reduce noise while preserving important features, and the second stage uses intelligent pattern recognition algorithms to cluster energy consumption patterns. Our proposed two-stage framework is evaluated on an industrial injection moulding system using a …