How Digital Maintenance Is Moving From Firefighting To A Strategic Lever

Jennifer Ritz 48 minutes ago

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European process manufacturers are under mounting pressure to deliver more output, with fewer people, from older assets – all while meeting tougher safety, ESG and reporting requirements. In this environment, the way plants manage maintenance has a direct impact on uptime, margins and licence to operate, not just on wrench time.

Why Maintenance Strategy Now Belongs In The Boardroom

For years, maintenance in process industries was treated as a cost of doing business – something that only got attention when lines stopped or regulators called. That mindset is increasingly at odds with reality: global demand for industrial machinery is projected to rise from 235 billion dollars in 2023 to 362 billion dollars by 2031, dramatically increasing the installed base that needs to be kept running safely and efficiently.

In complex, continuous processes, unplanned downtime is no longer a nuisance but a material financial risk: for the world’s 500 largest companies, unplanned outages are estimated to erode around 11% of annual revenue, with typical costs in Germany alone reaching about 147,000 euros per hour. As assets become more automated and interconnected – and as energy and raw materials stay volatile – maintenance moves from a back‑office activity to a strategic control point for availability, quality, energy consumption and risk.

The Five Structural Challenges Holding Plants Back

Across chemicals, pharmaceuticals, food and drink, water and broader manufacturing, the same structural obstacles keep maintenance teams on the back foot.

Aging Infrastructure and Life‑Extended Equipment
Many plants are operating machinery, utilities and safety systems well beyond their original design life, often without a reliable view of condition or history. Under pressure, teams improvise repairs, which pushes up unplanned downtime and makes long‑term planning difficult.
Skills Shortages and Knowledge Drain
Experienced technicians are retiring faster than they can be replaced, and in a recent SME survey, almost two‑thirds reported a lack of qualified personnel. Critical know‑how often lives in people’s heads or in scattered personal notes, so every departure increases the risk of repeat failures, quality issues or safety incidents.
Low Digital Maturity and Data Silos
Many maintenance organisations in Europe still rely on paper, spreadsheets and isolated point solutions to plan and log work. In 2024, 42% of small companies and 20% of mid‑sized companies had not even reached a basic level of “digital intensity”, limiting their ability to exploit sensors, analytics or even simple KPIs.
Budget Pressure and Short‑Term Focus
When maintenance is treated purely as a cost centre, investments in spares, condition monitoring, software or training are easy targets for cuts. The result is a “run to failure” culture that saves money in the short term but incurs indirect costs – overtime, scrap, missed deliveries – that can be two to ten times higher than direct maintenance spend.
Fragmented Systems and Unclear Accountability
In many plants there is no single, trusted view of assets, work history and responsibilities; information is scattered across maintenance, production, engineering and EHS. This fragmentation hides failure patterns, complicates compliance and prevents meaningful automation or benchmarking.

For readers of Process Industry Informer, these themes will be familiar – but the data shows they are now persistent structural issues, not temporary growing pains.

From Reactive To Predictive: A Practical Maturity Model

The Timly Maintenance Report 2026 distils plant practice in Europe into a four‑stage maturity model, which maps closely to what process engineers experience on the ground.

Maturity Stage	How Work Gets Done	Typical Characteristics
Reactive	Teams respond when something breaks.	Little or no asset history, long and unpredictable downtimes, high stress, heavy dependence on individual experts.
Preventive	Work is planned by fixed time or usage intervals.	Better reliability and documentation, but over‑maintenance and inefficient use of labour and spares.
Condition‑Based	Tasks are triggered by measured condition (inspections, sensors, process data).	Downtime and repair severity begin to fall; logs and inventories are partially digitised.
Predictive	Failures are anticipated using AI and IoT, and work is scheduled before breakdown.	High availability, strong integration with other systems, maintenance treated as a management and ESG tool.

Most European companies in the study sit somewhere between reactive and condition‑based maintenance, often with “islands of excellence” around critical assets. Industries with high asset values and strict safety regimes – such as oil and gas, chemicals, pharmaceuticals, automotive and aerospace – are more likely to run pilots in predictive maintenance, while public infrastructure, healthcare and smaller logistics operations remain heavily manual.

For practitioners, the real value of a maturity model is not the labels but the roadmap: understanding where you are today, where it makes sense to be in three years, and what steps will move the needle without disrupting production.

(Smart maintenance management made possible with Timly)

Technology Trends Reshaping Maintenance In Process Plants

Several long‑term trends are now converging to change what “good” looks like in maintenance – and they align closely with the needs of continuous and batch processing environments.

Digitisation and Automation of Routine Work
Moving away from paper and spreadsheets to digital workflows makes it easier to standardise inspections, generate work orders automatically and capture complete histories. In practice, this means fewer missed tasks, better coordination with production, and a solid data set for improvement projects.
AI and the Industrial Internet of Things
Connected sensors on pumps, drives, heat exchangers and other critical assets provide continuous streams of condition data – vibration, temperature, power draw, flow and more. Machine‑learning tools can highlight anomalies earlier than conventional trend charts, enabling dynamic maintenance scheduling that fits around campaigns and cleaning windows.
ESG and Regulatory Pressure as Change Driverstime
New reporting frameworks such as the EU Corporate Sustainability Reporting Directive (CSRD), the EU Taxonomy and due‑diligence rules require verifiable data on resource use, lifecycle impacts and safe operation. Maintenance becomes a lever to extend asset lifetimes, reduce energy use and prove compliance with standards like ISO 55000, ISO 9001 and sector‑specific safety codes.
Mobile and Cloud as the Default User Interface
In many European frontrunner countries – notably Scandinavia and the Netherlands – it is now normal for technicians to access work orders, asset histories and checklists via mobile devices at the point of work. Cloud‑hosted platforms allow multi‑site organisations to share standards, KPIs and master data, while still accommodating local plant realities.

Taken together, these trends move maintenance towards a role where it supplies trusted, real‑time information and recommendations to operations, engineering, finance and sustainability teams.

If you want to explore how these trends relate to your own plant, you can find more detail and practical examples at timly.com.

(Timly is helping maintenance leaders gain an advantage.)

Practical Steps For Maintenance Leaders In The Process Industries

The report highlights a set of pragmatic steps that plants across Europe are taking to escape firefighting mode and build more resilient maintenance organisations.

Start With A Clear Status Assessment
Before buying technology, leading organisations map their asset base, current processes and pain points, asking where data is missing, how work is triggered and where duplication occurs. Even a simple self‑assessment against the four‑stage maturity model can reveal quick wins and priority focus areas.
Treat Digital Maintenance As A Cross‑Functional Programme
Successful digitisation projects are rarely “IT installs a new system”. Instead, they involve maintenance, production, engineering, procurement, finance and HSE from the outset, with clear sponsorship and governance. This approach helps align requirements, manage change and avoid creating yet another silo.
Standardise Processes – Then Automate Them
Many of the most effective improvements come from agreeing standard inspection templates, failure codes and workflows across lines and sites. Once these are in place, digital tools can automate scheduling, escalation and documentation, making audits and cross‑site comparisons far easier.
Build A Central, Trusted Asset And Maintenance Database
Moving to a single source of truth for asset master data, locations, ownership, maintenance plans and histories is a recurring success factor. Plants that have taken this step report fewer lost tools and instruments, better spare‑parts planning and more confident decision‑making on repair‑vs‑replace.
Progress In Small, Focused Iterations
Rather than attempting a “big bang” rollout, many organisations begin with a pilot area – a line, utility system or asset family – and refine their approach before scaling. This reduces risk, allows local champions to emerge and generates evidence to support further investment.
Invest In People, Not Just Platforms
Because skills and acceptance are recurring bottlenecks, leading plants invest in structured training and change‑management, not just technical implementation. Involving technicians in design choices, offering hands‑on trials and maintaining transparent communication helps build trust and lasting adoption.

Digital maintenance management platforms such as Timly’s are one way organisations are putting these principles into practice – for instance by using QR‑coded assets, mobile apps and open APIs to integrate with existing ERP, CAFM or ticketing systems without ripping and replacing established tools. For readers interested in concrete case studies from sectors such as timber processing, refrigeration and IT services, these are available to explore at timly.com.