Maintenance is vital to many industries, particularly in manufacturing, real estate, hospitality, oil, gas, power, IT, and even food and beverage. There are two basic types of maintenance: reactive and preventive. Reactive maintenance is done when something breaks down unexpectedly. This is the type of maintenance you don’t want to find your team performing, as this would mean downtime and often, higher costs. Preventive maintenance, on the other hand, involves the careful planning and scheduling of performance and safety checks to eventually ensure that downtimes and the need for reactive maintenance are minimized.
Aside from using modern tools such as maintenance management software, including computerized maintenance management systems (CMMS), knowing what’s going on in the field can help reliability managers develop better preventive maintenance plans. This also involves looking at what other maintenance executives are doing to improve their processes. So, for your convenience, we’ve rounded up the latest maintenance statistics that can help you streamline and strengthen your maintenance plans and strategies.
Maintenance Statistics Table of Contents
General Maintenance Statistics
As equipment and buildings get older, they often require more maintenance. Furthermore, with more companies and facilities being developed, more assets need maintenance. This, among other aspects, contributes to the continuous growth of the maintenance market and those related to it.
- The global maintenance, repair, and operations market’s estimated value in 2020 was $616.01 billion. It is projected to register a value of $701.3 billion by 2026, growing at a CAGR of about 2.19%. (Mordor Intelligence, 2020)
- Meanwhile, the global predictive maintenance market is expected to grow to $23.5 billion by 2024. (IoT Analytics, 2019)
- Moreover, the global CMMS software market is estimated to reach $1.26 billion by the end of 2026 at a CAGR of 9.8% from 2020 to 2026. (Markets and Research, 2020)
- What’s the cost of outdated equipment? According to the latest data, US factories use an estimated $40 billion worth of outdated equipment, which costs them $50 billion in unexpected equipment downtimes. (UpKeep, 2019)
- According to maintenance professionals, the leading causes of unscheduled equipment downtime are aging equipment (34%), mechanical failure (20%), operator error (11%), lack of time for maintenance (9%), and poor equipment design (8%). (Plant Engineering, 2020)
- In 2020, 46.91% of surveyed companies in North America reported that they spent 21% to 40% of their operating budget on the cleaning and maintenance of their equipment and supplies. Meanwhile, 35.67% spent 1% to 20% of their budget. On the other hand, 2.25% of companies spent more than 80% of their operating budget on equipment maintenance alone. (CMM, 2020)
- Meanwhile, 18% of companies spend 40 hours or more per week on maintenance. (Plant Engineering, 2020)
- In general, maintenance and reliability teams have remained financially stable through the COVID-19 outbreak. Around 66% of maintenance teams say their budget is either staying the same or increasing in 2021. (UpKeep, 2021)
- The top challenges encountered by maintenance teams have to do with hiring, onboarding, and retaining people (48%), streamlining processes (27%), and successful technology adoption (25%). (Plant Engineering, 2020)
Source: Plant Engineering
Maintenance Strategies Statistics
Ever wondered how businesses in different industries handle maintenance? The maintenance statistics below show the different strategies utilized in industries where maintenance is a huge deal.
- In 2020, 76% of companies in the manufacturing industry worldwide prioritized preventive maintenance. (Plant Engineering, 2020)
- Meanwhile, 60% of manufacturing companies still performed reactive maintenance. (Plant Engineering, 2020)
- The other maintenance strategies utilized in the manufacturing industry are CMMS (52%), predictive maintenance using analytics tools (41%), and reliability-centered maintenance using operational data analysis (22%). (Plant Engineering, 2020)
- In 2020, the majority of facility management companies (90.61%) provided in-house training for their maintenance staff. On the other hand, 51% sought the services of distributors and vendors, while 24.86% opted for online training providers. Only 16.02% enlisted a third-party, industry-recognized certifying body. (CMM, 2020)
Technology Adoption in the Maintenance Field
The maintenance market is among those most penetrated by automation and management technologies. However, the maintenance statistics below show that while more companies now adopt modern technologies and software, some have yet to explore their advantages.
- 50% of leaders and engineers in the manufacturing industry report that they use CMMS. Meanwhile, 29% rely on automated maintenance schedules generated by their manufacturing scheduling system, and 18% use a generic computerized calendar such as Microsoft Outlook. On the other hand, 8% utilize enterprise asset management tools. (Plant Engineering, 2020)
- In all, 66% of maintenance professionals from various industries say they use CMMS to track their maintenance program, a 24% increase from 2019. This suggests that COVID-19 might have accelerated digital transformation in the maintenance and reliability sector. (UpKeep, 2021)
- 74% of CMMS users believe that this tool improves productivity, while 58% consider it cost-effective in general. Furthermore, 57% of users see its ease of use as an advantage. (Plant Engineering, 2020)
- Moreover, 51% of CMMS users think that the tool helps reduce downtime. (Plant Engineering, 2020)
- Around 9% of manufacturing entities leverage industrial internet of things (IoT) and cloud computing tools and technologies. (Plant Engineering, 2020)
- Moreover, 32% of maintenance executives believe that IoT will help them better understand machine health, while 27% think it can help them better predict and prevent equipment shutdowns. Another 25% believe IoT will change the way their maintenance personnel work and interact with all levels of their operation. (Plant Engineering, 2020)
- It is estimated that industrial IoT will generate around $800 billion in economic value by 2024. (UpKeep, 2019)
- In relation to this, the global discrete manufacturing industry was already projected to spend $119 billion in IoT in 2019, while the process manufacturing industry was estimated to spend $78 billion. Meanwhile, the transportation and utility industries were projected to spend $71 billion and $61 billion, respectively. (IDC, 2019)
- Moreover, it is also projected that about $4.1 billion will be invested in augmented and virtual reality (AR/VR) for industrial maintenance by 2024. (IDC, 2020)
- 8% of companies use handheld or mobile devices for maintenance tasks: 23% use them for communication, 9% for scheduling and disseminating information about the equipment and its history, and 6% have the mobile devices fully integrated into their CMMS or IIoT system. (Plant Engineering, 2020)
Source: Plant Engineering
Adoption Challenges
- Maintenance cost in manufacturing can get pricey. As such, 47% of manufacturing companies and teams still use in-house spreadsheets for maintenance schedules, while 46% utilize clipboards and paper records of maintenance rounds. (Plant Engineering, 2020)
- Around 33% of respondents say new software is difficult or very difficult to adopt for their teams. (UpKeep, 2021)
- About 30% of maintenance professionals say they do not use handheld or mobile devices for maintenance tasks, and that they have no plans of using them in the future. (Plant Engineering, 2020)
- 25% of maintenance leaders think IoT will have no impact on their operations. (Plant Engineering, 2020)
Maintenance Jobs Statistics
As a perpetually growing market, the maintenance field generates many career and employment opportunities every year. Here are some essential maintenance jobs statistics.
- As of 2020, the median pay for general maintenance and repair workers in the United States is $40,850 per annum. (U.S. Bureau of Labor Statistics, 2021)
- In 2019, there were a whopping 1,516,400 general maintenance and repair jobs in the US. (U.S. Bureau of Labor Statistics, 2021)
- The real estate and leasing industry hired the most maintenance and repair workers in the US in 2019 at 22%. It is followed by manufacturing (13%), government (12%), educational services (8%), and healthcare and social assistance (8%). (U.S. Bureau of Labor Statistics, 2021)
- Meanwhile, the manufacturing industry pays the highest median annual salary ($47,580) to general maintenance and repair workers. The government sector, on the other hand, pays a median annual salary of $44,060. Maintenance workers in the real estate industry get a median annual pay of $38,720. (U.S. Bureau of Labor Statistics, 2021)
- The employment rate for general maintenance and repair workers in the US is expected to grow by 4% come 2029. (U.S. Bureau of Labor Statistics, 2021)
- In 2020, Alaska was named the best state for maintenance technicians. The average annual salary of maintenance workers in the state is $52,913, with the highest 10% earning around $73,000 and the lowest 10% receiving about $38,000 per year. (Zippia, 2020)
- The latest US jobs data also shows an unemployment rate of 2.3% among maintenance and repair workers. (U.S. News, n.d.)
- As of 2020, there are around 526,000 electrical and electronic equipment repairers, mechanics, and installers in the US. (Bureau of Labor Statistics, 2021)
Source: U.S. Bureau of Labor Statistics
How can sustainability practices reduce maintenance costs?
With an increasing focus on sustainability, maintenance teams are exploring eco-friendly practices that reduce costs while minimizing environmental impact. Sustainable maintenance practices not only align with broader corporate responsibility goals but also contribute to long-term cost savings by improving equipment efficiency, reducing waste, and conserving resources.
- Energy-Efficient Equipment: Using energy-efficient machinery and appliances reduces operational costs by lowering electricity consumption. Regular upgrades to energy-efficient models can also extend equipment lifespan, requiring less frequent replacements.
- Preventive and Predictive Maintenance: Sustainable practices emphasize preventive and predictive maintenance over reactive approaches. By scheduling regular inspections and using predictive tools, companies reduce emergency repairs, lower downtime, and cut down on resource waste.
- Reducing Waste and Extending Asset Life: Sustainable maintenance practices prioritize prolonging asset life. Maintenance teams can adopt remanufacturing or refurbishing methods to extend equipment use instead of disposing of or replacing it. This approach reduces waste and cuts costs associated with purchasing new equipment.
- Using Eco-Friendly Lubricants and Cleaning Agents: Switching to biodegradable or eco-friendly lubricants and cleaning agents reduces the environmental impact of maintenance operations. These products often have less harmful disposal processes and can contribute to safer working environments for staff.
- Sustainable Inventory Management: Effective inventory management minimizes surplus parts, reduces waste, and allows for optimal resource use. By using sustainable inventory practices, teams can avoid over-ordering and minimize the ecological footprint associated with material storage.
- Water Conservation in Maintenance: For industries where equipment cooling or cleaning requires water, sustainable water management practices, like reusing or recycling water, can significantly reduce water consumption and associated costs.
- Compliance with Environmental Standards: Adopting sustainable practices helps companies meet environmental compliance standards, reducing the risk of regulatory fines and enhancing brand reputation. Maintaining compliance can also prevent sudden operational interruptions due to non-compliance issues.
Leverage These Maintenance Statistics to Improve Your Strategies
Indeed, maintenance is an inevitable aspect of the majority of businesses. To understand what the benefits of maintenance are and make the most of it, you need to make plans and decisions not just carefully but strategically as well. By looking at maintenance statistics, you can develop a plan and strategy backed by actual industry data. In this way, your plans will be more efficient, helping ensure that you minimize maintenance costs and losses caused by equipment breakdowns and unexpected downtimes.
Aside from factoring in these stats and facts while planning, it is also recommended that you take advantage of maintenance management software. Most of these tools integrate with other business systems that you’re probably already using, so adoption shouldn’t be much of a challenge. Furthermore, these programs are designed to streamline maintenance processes such as scheduling, notification, and documentation. As such, your team will no longer forget scheduled maintenance again, and your staff won’t have to scramble through piles of system documents.
Key Insights
- Maintenance Types:
- Reactive Maintenance: Performed after equipment failure, leading to downtime and higher costs.
- Preventive Maintenance: Planned maintenance to minimize downtimes and avoid unexpected breakdowns.
- Market Growth:
- The global maintenance, repair, and operations market was valued at $616.01 billion in 2020, projected to reach $701.3 billion by 2026.
- Predictive maintenance market expected to grow to $23.5 billion by 2024.
- CMMS software market estimated to reach $1.26 billion by 2026.
- Cost of Outdated Equipment:
- US factories use an estimated $40 billion worth of outdated equipment, resulting in $50 billion in unexpected downtimes.
- Causes of Downtime:
- Leading causes: aging equipment (34%), mechanical failure (20%), operator error (11%), lack of maintenance time (9%), poor equipment design (8%).
- Budget and Time Investment:
- 46.91% of North American companies spent 21% to 40% of their budget on maintenance.
- 18% of companies spend over 40 hours per week on maintenance.
- Technology Adoption:
- 66% of maintenance professionals use CMMS, improving productivity and reducing downtime.
- 74% of CMMS users find it improves productivity; 58% find it cost-effective.
- Industrial IoT is projected to generate $800 billion in economic value by 2024.
- Challenges:
- Major challenges include hiring, onboarding, and retaining staff (48%), streamlining processes (27%), and technology adoption (25%).
- Maintenance Jobs:
- Median pay for general maintenance workers in the US is $40,850 per annum.
- The employment rate for maintenance workers is expected to grow by 4% by 2029.
- Alaska offers the highest average salary for maintenance technicians.
FAQ
- What are the main types of maintenance? There are two primary types of maintenance: reactive and preventive. Reactive maintenance is performed after equipment breaks down, while preventive maintenance involves planned activities to prevent breakdowns and minimize downtime.
- How large is the maintenance market? The global maintenance, repair, and operations market was valued at $616.01 billion in 2020 and is projected to grow to $701.3 billion by 2026.
- Why is preventive maintenance important? Preventive maintenance is essential as it helps minimize unexpected downtimes, reduces repair costs, and extends the lifespan of equipment by ensuring regular checks and maintenance.
- What technologies are commonly used in the maintenance field? Common technologies include Computerized Maintenance Management Systems (CMMS), Industrial Internet of Things (IoT), cloud computing, and augmented/virtual reality for maintenance tasks.
- What are the leading causes of equipment downtime? The leading causes of equipment downtime are aging equipment (34%), mechanical failure (20%), operator error (11%), lack of maintenance time (9%), and poor equipment design (8%).
- How does technology adoption impact maintenance? Adopting technologies like CMMS improves productivity, reduces downtime, and streamlines maintenance processes. It also helps in predictive maintenance by providing insights into equipment health and performance.
- What challenges do maintenance teams face? Maintenance teams face challenges in hiring, onboarding, and retaining staff, streamlining processes, and adopting new technologies effectively.
- What is the job outlook for maintenance workers? The employment rate for maintenance workers is expected to grow by 4% by 2029, with the real estate and manufacturing industries being the largest employers.
- How much do maintenance workers earn? As of 2020, the median annual pay for general maintenance workers in the US is $40,850. The highest salaries are in the manufacturing industry, with a median pay of $47,580 per year.
- What role does IoT play in maintenance? IoT helps maintenance teams better understand machine health, predict and prevent equipment shutdowns, and improve the efficiency and effectiveness of maintenance operations.
References:
- Chan, R. (2019, May 23). 35 of the most interesting statistics about maintenance and facility management. Retrieved from UpKeep
- CMM. (2020, April). What percentage of your operating budget is spent on cleaning/maintenance equipment and supplies?. Retrieved from Statista
- CMM. (2020, April). Who provides training for your cleaning/maintenance staff?. Retrieved from Statista
- IDC. (2020). Worldwide Spending on Augmented and Virtual Reality Forecast to Deliver Strong Growth Through 2024, According to a New IDC Spending Guide. Retrieved from IDC
- IDC. (2019). IDC Report: IoT Spending to Reach More than $1 Trillion by 2022. Retrieved from Finley
- Markets and Research. (2020, April). Global Computerized Maintenance Management System (CMMS) Software Market 2020 by Company, Regions, Type, and Application, Forecast to 2026. Retrieved from Markets and Research
- Mordor Intelligence. (2020). MAINTENANCE, REPAIR, AND OPERATIONS (MRO) INDUSTRY – GROWTH, TRENDS, COVID-19 IMPACT, AND FORECASTS (2021 – 2026). Retrieved from Mordor Intelligence
- Parker, K. (2020, March 11). An evolutionary challenge faces the maintenance function. Retrieved from Plant Engineering
- Scully, P. (2019, October 8). Predictive Maintenance Companies Landscape 2019. Retrieved from IoT Analytics
- UpKeep. (2021). State of Maintenance 2021 Report. Retrieved from UpKeep
- U.S. Bureau of Labor Statistics. (2021, April 9). General Maintenance and Repair Workers. Retrieved from U.S. Bureau of Labor Statistics
- U.S. News. (n.d.). Maintenance and Repair Worker. Retrieved from U.S. News
- Zippia. (n.d.). BEST STATES FOR A MAINTENANCE TECHNICIAN. Retrieved from Zippia
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