1、SENSEYE PREDICTIVE MAINTENANCE The True Cost of Downtime 2024How much do leading manufacturers lose through inefficient maintenance?Find out more: Maintenance stops downtime costs crippling manufacturingUnplanned downtime is now a cost that major manufacturers cannot afford.In the Automotive sector,

2、the cost of an idle production line at a big plant is now$695 million a year,1.5 times higher than five years ago.In a Heavy Industry plant,it is$59 million,1.6 times higher than in 2019.So unplanned downtime now costs the worlds 500 biggest companies 11%of their revenues.That totals$1.4 trillion eq

3、uivalent to the annual GDP of a major industrial nation like Spain.These are the key findings of this report,a review of the true costs of downtime to manufacturers and industrial organizations over the past five years.At the bottom end,the costs of a lost hour are now$36,000 in Fast Moving Consumer

4、 Goods.At the top end,they are$2.3 million in the Automotive sector or more than$600 a second.Faced with these kinds of costs,companies have been forced to try to cut downtime ruthlessly.Most have succeeded.Since 2019,almost every sector has cut the number of downtime hours suffered.Heavy Industry h

5、as slashed it to nearly a third of 2019 levels.Only these efforts have stopped the overall costs of downtime from spiralling out of control.Firms have brought in powerful new technology to minimize production hours lost.The Internet of Things has allowed them to collect data on the condition of thei

6、r machines.Predictive Maintenance(PdM)has allowed them to avoid machine failures on the one hand and the costs of over-maintenance on the other.Frequent scheduled maintenance keeps machines healthy,but it also has considerable costs in unnecessarily closed lines and the need to keep up stocks of exp