Predictive maintenance brings significant benefits for industries

The global consultancy Roland Berger has made a research on predictive maintenance in collaboration with the lubricant oil company Castrol. 

According to the research report the attitudes towards maintenance are changing. Maintenance is increasingly seen as a strategic business function, as opposed to a necessary evil. Through predictive maintenance manufacturers look for decreasing maintenance costs and downtime, and for increasing asset lifecycles.

Oil and gas industries are among the first industry sectors to use predictive maintenance. According to the report¹ of US Department of Energy the adoption of predictive maintenance has brought significant benefits for these industries:

- Return on investment 10 times

- Reduction in maintenance costs 25 % - 30%

- Elimination of breakdowns 70 % - 75 %

- Reduction in downtime 35 % - 45 %

- Increase in production 20 % - 25 %

Many issues need to be addressed before predictive maintenance can be made available for manufacturing industry at a large scale. Predictive maintenance solutions that cater for the needs of wide and complex industries must be developed, which can be a challenge for solution providers. Moreover, retrofitting older machines without built-in sensors and data capture functionality for purposes of predictive maintenance may turn out to be costly. Another issue that may need to be overcome is skepticism and reservations about new maintenance technology by maintenance personnel that is not willing to let go of more traditional maintenance methods.

OptiScan’s customer KiiltoClean who has been using Abakus FieldWork since 2014 has positive experience on predictive maintenance as well. "In many cases our solutions are business critical for our customers. If machines are out of order, it can mean breaks in the production. Service breaks agreed beforehand, predictive maintenance and remote control reduce unnecessary breaks in the production. Without the Abakus FieldWork system we would not be able to manage maintenance and installation as flexibly”, says CIO Tuomas Vepsäläinen at Kiilto Family.

Read more on KiiltoClean’s case story on how the company solved challenges related to predictive maintenance and management of mobile workforce. 

The Roland Berger’s report can be found here.

Predictive Maintenance – Is the timing right for predictive maintenance in the manufacturing sector?
Roland Berger, November 2014

Roland Berger, founded in 1967, is the only leading global consultancy of German heritage and European origin. With 2,400 employees working from 36 countries, we have successful operations in all major international markets. Our 50 offices are located in the key global business hubs. The consultancy is an independent partnership owned exclusively by 220 Partners.

¹US Department of Energy O&M Best Practise Guide, 2010



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