In many industrial companies, maintenance continues to suffer from a poor image. When machines and systems run smoothly, maintenance is often dismissed as a mere cost factor.
Yet when malfunctions occur or equipment requires servicing, the resulting downtimes frequently prompt criticism from both management and production teams. In these moments, maintenance is unconsciously cast as the scapegoat.
A study conducted by the Maintenance 4.0 project consortium – funded by the Austrian Research Promotion Agency (FFG) and the Federal Ministry for Transport, Innovation, and Technology (bmvit) – reveals that these assessments are more than just anecdotal. In expert interviews, the researchers examined the perceived importance of maintenance. The findings were clear: Maintenance is not expected to emerge from the shadow of production any time soon. Most anticipate that little will change – at best, a modest strategic upgrade might occur.
Digitalization opens up opportunities
These small expectations are particularly striking in the context of digital transformation. Because: Maintenance is poised for a fundamental shift.
As machines, systems, tools, and vehicles grow increasingly complex, the role of IT in maintenance becomes more critical. To remain effective, maintenance must evolve in parallel. At the same time, digitalization opens up new opportunities to cut costs while generating added value.
Innovative approaches such as condition-based maintenance and predictive maintenance are gaining traction. These two methods significantly reduce unplanned downtimes and contribute to a measurable increase in overall equipment effectiveness (OEE).
Transitioning from maintenance technicians to asset managers
Digitalization is transforming not only technologies but also the perception of roles within maintenance. The scope of responsibilities is expanding significantly: Traditional maintenance technicians are evolving into asset managers.
This means that the entire life cycle of an asset is coming into focus – from selecting and designing suitable equipment, to installation and operation, all the way to decommissioning.
If this holistic approach takes hold, the criteria for measuring success will also change. Instead of focusing solely on maintenance costs, attention will turn to the total cost of ownership (TCO).
Asset management creates added value
Strategic and sustainable asset management not only improves a company’s cost structure but can also have a direct impact on productivity and output. This influence becomes evident in several key areas, as illustrated by the following three potentials:
Potential 1: Leveraging knowledge for process optimization
Over the course of an asset’s lifecycle, maintenance and asset management generate valuable insights. When systematically analysed and applied, this knowledge can help continually optimize production processes and reduce waste.
Potential 2: Enhancing product quality through system integration
When assets are seamlessly integrated and operate reliably, product quality improves. This leads to fewer warranty claims and lower associated costs. Moreover, consistently high product quality strengthens brand reputation, boosts customer satisfaction, and fosters long-term loyalty.
Potential 3: Resource efficiency as a brand image advantage
Well-integrated and optimally tuned equipment consumes fewer resources, cutting costs while supporting environmental sustainability. This dual benefit not only improves the bottom line but also strengthens the company’s public brand image.
Equipping maintenance teams with new skills
To fully unlock these potentials, maintenance personnel must broaden their skill sets. In addition to strong foundations in mechanics and electronics, IT expertise is becoming increasingly essential. A solid understanding of business contexts is also critical, enabling professionals to translate technical and technological data into meaningful, value-driven use cases.
Finally, future asset managers must embrace a mindset of continuous learning and stay open to emerging topics and innovations.
Fostering cultural change
These developments have the potential to reshape the perception of maintenance far more positively than current expert forecasts suggest. This transformation is especially important for attracting the next generation of skilled workers – an urgent challenge many companies face. However, technical advancements alone are not enough. Organizational awareness and active support are essential for meaningful change.
To support this transition, the Maintenance 4.0 project consortium has identified two key levers for success:
- Measure the value of maintenance: Performance should be assessed using carefully selected maintenance KPIs that align with the company’s strategic objectives.
- Communicate successes internally: Maintenance achievements must be clearly communicated across the organization. This transparency not only reinforces the importance of maintenance but also represents a significant cultural shift for many companies.
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