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20 July 2023

What are the two keys to success in Predictive Maintenance?

Successfully implementing predictive maintenance at scale is about technology, right? Having the technology to collect the necessary data, and the advanced analytics to predict failure? 

Not quite, according to Siemens’ major new survey of global manufacturers. 

It’s not just about technology

Yes, the data collection has to be in place. But our research suggests that the key factor in project success is a manufacturer’s level of cultural maturity when it comes to maintenance. 

Predictive maintenance is not a plug-and-play commodity. It is a mindset.

Cultural maturity is all about how ready an organization is to adopt a new maintenance mindset, and how clear the firm is about the business goals it wants to achieve.  

Data + Culture = Success

The report identifies two important factors, both of which need to be in place to make a predictive maintenance project likely to succeed.

  1. Data maturity. How close is the organization to being able to collate and exploit the data needed for predictive maintenance at scale?
  2. Cultural maturity. Does the organization already have the ways of thinking, clarity about goals and top-level buy-in that form the culture that leads to success with PdM? 

Are global manufacturers ready for Predictive maintenance? 

New research in Senseye’s ‘Readiness for predictive maintenance at scale’ report reveals:

  • In many cases, the data is there. Eight out of ten forward-looking firms making enquiries about PdM now have the data-capture and storage capabilities to make Artificial Intelligence-driven Predictive maintenance at scale realistic. 
  • Cultural maturity is lagging behind. Only 46% of major manufacturers engaging with Senseye have the cultural maturity required to make successful deployment likely.
  • Cultural maturity has clear quantifiable benefits. There is a very clear correlation between high levels of cultural maturity and lower levels of unplanned downtime and downtime costs. Organizations with the highest levels of cultural maturity also enjoy significantly better Overall Operational Efficiency (OEE) than those with the least developed maintenance cultures. 
  • Levels of cultural maturity are growing as predictive maintenance goes mainstream. In 2018 and 2019 the average score for cultural maturity in our readiness index was around 0. For the past three years it has been above 150. Attitudes towards maintenance are changing fast at forward-looking manufacturers.

Data maturity outrunning cultural maturity

Only one in five (19%) manufacturers who have contacted Siemens are at the top two levels for organizational culture. By contrast, more than half (57%) have reached the top two levels of data maturity. Most forward-looking firms have the data in place. 

How to improve cultural maturity

Organizations that succeed with predictive maintenance projects have four cultural factors in common: they are objective and metric-driven; there is buy-in from the very topend users are included in projects early; and they get expert support from partners.

For more on how to develop the data and cultural maturity, and boost the chance of Predictive Maintenance success, read the full report here.

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