Your Maturity Result: Level

At this moment, things could be looking better. Limited digital processes are in place, there is restricted access to the data generated from the machines and processes. Additional sensors and improvements to the operational/information technology infrastructure need to be made. There is a limited willingness towards the digital transformation from the management side. No data-driven maintenance strategies utilized for analytics. 

There is a lot to be improved, but fear not, taking the first step towards data-driven maintenance is always the hardest.  

Good, you are on your way towards data-driven and mature maintenance strategies. You have sufficient infrastructure for information/operational technology. There is asset visibility and standardization in some processes and activities. There is an understanding from the management about the need to adopt more mature maintenance strategies. But there is work to be done if you want to successfully move toward data-driven maintenance.

Great work! Your organization is doing good maintenance maturity-wise and moving confidently towards data-driven maintenance strategies. Data is analysed to capture valuable information in order to understand the business insights (e.g. proactive activities identification by crossing error data, product number, machine downtime, etc.) and there is a clear digitalization agenda (e.g. resources and activities are defined) shared at all hierarchical levels. There is always room for improvements if you want to embrace and benefit from data-driven maintenance strategies fully.

Amazing work! Your organization’s maintenance maturity should be a motivation for other companies who want to embrace data-driven maintenance strategies. Maintenance decision-making is supported by insights from data and utilization of advanced algorithms determining the remaining lifecycle of your assets. Digital development is a well-established company practice at all hierarchical levels. Now it is just a matter of fine-tuning some elements and you can reap the benefits of data-driven maintenance fully.

Congratulations. You are the definition of execution excellence in data-driven maintenance! With the maintenance maturity of the highest grade, your organization can be counted in the front-runner section across industries. Decision making is performed based on automatically synchronized data from the whole organization’s network (e.g. suppliers’ suppliers and customers’ customers) and digital development is a well-established practice at all hierarchical levels within the whole organization’s network.

If you want to cement your position as the powerhouse in data-driven maintenance, reach out to us, we might have some ideas for improvement.


  

Scores

Governance
-25%
Competence
-25%
Technology
-25%
Value Creation
-25%

Overview


  

Overall Maintenance Maturity Score

You scored level: 1


  

How you benchmark against the industry

Looking at the scale of the basics of CBM and PdM to advanced implementation, we can distinguish four different levels

Level 1

Visual inspections

Periodic physical inspections, where conclusions are solely based on inspectors’ expertise.

Level 2

Instrument inspections

periodic inspections, where conclusions are based on a combination of inspectors’ expertise and instrument read-outs.

Condition monitoring

continuous real-time monitoring of assets where alerts are given based on pre-established rules of critical levels

Level 3

Big data/advanced analytics

continuous real-time monitoring of assets, with alerts sent based on predictive techniques and predicting future events.

Level 4

Market Position

Looking at the market, there is no shortage of ambitions, ambitions are high. A majority of companies is planning to use data-driven predictive maintenance at some point in time. Where one in three companies (33%) wants to do something within the next 5 years. However, currently two thirds (66%) are still at level 1 or 2. Another 23% is at level 3, already continuously monitoring asset conditions in real-time. Only 11% has achieved level 4, monitoring assets in real-time and predicting future events.

How you benchmark against the idnustry

Predicting Future Events

Your organization mostly makes use of visual inspections to assess the condition of your assets. This puts you on maturity level 1 out of 5. 66% of companies are at level 1 or 2, however, this makes you part of the laggards for adoption. It is good that you are monitoring your assets, since most companies are only recently making their first moves, or not even get to this point due to various reasons. We notice that the technological gap of your segment with the frontrunners is widening, due to the competitive edge your more advanced competitors have. Don’t worry, there are steps to take right now that can speed up your maturity. We would gladly help you with that. 

Your organization mostly uses instrument inspections to investigate the condition of your assets. This puts you on maturity level 2. Being on level 2 on maturity regarding data-driven maintenance puts your organization in the majority of the industry. 66% of companies are at level 1 or 2, however, this makes you part of the laggards section for adoption. It is good that you are monitoring and taking your asset’s health seriously, that’s already an important step to make. But the technological gap between your more advanced competitors is widening if you do not implement more elaborate data-driven maintenance strategies. It might be the right time to switch it up and become part of the front-runners? There are steps to take right now that can put you in front of the majority fast. We would gladly help you out with that.

Continuously monitoring asset condition in real-time puts your organization on maturity level 3 with 23% of the companies. Being on level 3 on maturity regarding data-driven maintenance puts your organization ahead of the majority of the industry. Utilizing condition-monitoring to examine the health status of your assets is illustrating the strong forward-thinking digital approach of your company. You are steps ahead and doing better than most of the industry in terms of real-time condition-monitoring, but now is not the time to feel comfortable since the competition is never resting. Why not stay ahead, go for the top and predict the future? We would gladly help you out reaching the top tier.

Being on level 4 on maturity regarding data-driven maintenance puts your organization in the leading group of the industry with only 11% of other companies at the same level. Strong digital development is at the core of your organization and the benefits of this are clear. You are utilizing real-time condition monitoring and advanced predictive algorithms to see into the future of your asset health. It feels great to be in the leading group of the industry, but why not be the best? We would gladly help you to be the powerhouse in data-driven maintenance.

Being on level 5 on maturity regarding data-driven maintenance defines your organization as an absolute innovator and example for others to follow without a doubt! Digital development is at the core and backbone of your organization enabling you to enjoy the benefits other companies are actively chasing. Your organization is the leader in data-driven maintenance and is constantly looking to reach perfection, setting the bar even higher each time. Perhaps it is possible to push the bar a bit higher? We would gladly investigate with you where the limits of data-driven maintenance excellence could be.

Looking at the market, there is no shortage of ambitions, ambitions are high. A majority of companies is planning to use data-driven predictive maintenance at some point in time. Where one in three companies (33%) wants to do something within the next 5 years. However, currently two thirds (66%) are still at level 1 or 2. Another 23% is at level 3, already continuously monitoring asset conditions in real-time. Only 11% has achieved level 4, monitoring assets in real-time and predicting future events.

Recommendations

Below are recommendations per category to achieve higher maintenance maturity levels.

Benefits

Book a time to discuss with any of our consultants how we can help you to improve your maintenance maturity and be ready for data-driven maintenance. Organizations with data-driven maintenance maturity of Level 4 and higher benefit from:

Reduction of asset shutdown time 25%

Maintenance cost reduction of 20%

Reduction of safety, health, environment & quality risks of 14%

Lifetime extension of ageing asset 20%

Increase of average asset durability of 80%

Factory output increase 5-200%

Productivity increase 5-160%

OEE increase 3-50%

Quality cost reduction 5-90%

Product cost reduction 5-40%

Energy efficiency 2-50%

Inventory reduction 10-90%

Lead time reduction 10-90%

Change-over shortening 30-70%

Lot size reduction 50-90%