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Toward Industry 4.0: How Predictive Maintenance Helps Metal Manufacturing Address Cost Pressures and Sustainability Challenges
Written by Amikon Limited
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As a seasoned expert in the field of automation spare parts, Sandy has dedicated 15 years to Amikon, an industry-leading company, where she currently serves as Director. With profound product expertise and exceptional sales strategies, she has not only driven the company's continuous expansion in global markets but also established an extensive international client network.
Throughout Amikon's twenty-year journey, Sandy's sharp industry insights and outstanding leadership have made her a central force behind the company's global growth and sustained performance. Committed to delivering high-value solutions, she stands as a key figure bridging technology and markets while empowering industry progress.
This is my linkedin:
As a seasoned expert in the field of automation spare parts, Sandy has dedicated 15 years to Amikon, an industry-leading company, where she currently serves as Director. With profound product expertise and exceptional sales strategies, she has not only driven the company's continuous expansion in global markets but also established an extensive international client network.
Throughout Amikon's twenty-year journey, Sandy's sharp industry insights and outstanding leadership have made her a central force behind the company's global growth and sustained performance. Committed to delivering high-value solutions, she stands as a key figure bridging technology and markets while empowering industry progress.
Metals are crucial foundational materials for global development, driving social progress in the construction, infrastructure, and engineering industries. To maintain profitability, metal manufacturing—across aluminum, steel, zinc, copper, and others—must address cost pressures from three key areas: global competition, shifts in the skilled workforce, and increasingly stringent carbon emission regulations.
Currently, approximately 60% of the world's GDP and over 50% of companies have committed to achieving net-zero emissions by 2050. Therefore, while reducing carbon emissions is a critical global goal, for metal manufacturers, meeting this target will increase costs, compliance burdens, and operational complexity. At the same time, intensified global competition is driving pricing pressures, while the large-scale retirement of skilled workers is creating knowledge gaps in production processes.
The metal manufacturing industry stands at a turning point, as encapsulated by the adage: "What got you here won’t get you there." Industry transformation is imperative. This transformation is Industry 4.0, which will enable new ways of thinking and production methods, achieving the next level of cost reduction essential for sustainable future development. For metal manufacturers moving toward Industry 4.0 and adopting smart manufacturing, the primary starting point is cost reduction—with a particular focus on an area that remains under-optimized and underutilized: equipment maintenance.
Currently, approximately 60% of the world's GDP and over 50% of companies have committed to achieving net-zero emissions by 2050. Therefore, while reducing carbon emissions is a critical global goal, for metal manufacturers, meeting this target will increase costs, compliance burdens, and operational complexity. At the same time, intensified global competition is driving pricing pressures, while the large-scale retirement of skilled workers is creating knowledge gaps in production processes.
The metal manufacturing industry stands at a turning point, as encapsulated by the adage: "What got you here won’t get you there." Industry transformation is imperative. This transformation is Industry 4.0, which will enable new ways of thinking and production methods, achieving the next level of cost reduction essential for sustainable future development. For metal manufacturers moving toward Industry 4.0 and adopting smart manufacturing, the primary starting point is cost reduction—with a particular focus on an area that remains under-optimized and underutilized: equipment maintenance.
Maintenance Optimization
According to industry estimates, in metal manufacturing, a 10% reduction in maintenance costs can lead to a 30% increase in profitability. To achieve benefits of this magnitude, leading metal manufacturers are shifting toward proactive maintenance enabled by condition monitoring. This transition from reactive to preventive maintenance allows manufacturers to better predict and manage asset health at a lower cost and at more opportune times. Data from Deloitte indicates that predictive maintenance can, on average, increase productivity by 35%, reduce equipment failures (and unplanned downtime) by 70%, and lower maintenance costs by 25%.
Unplanned downtime is a pain point for all manufacturing sectors, and its cost is particularly high in metal manufacturing. Large steel companies can spend as much as $4 billion annually on maintenance. Currently, approximately 20–25% of maintenance expenses are dedicated to addressing unplanned downtime, equivalent to about $900 million per year. With an appropriate proactive maintenance strategy, a significant portion of these expenses could have been avoided. For example, a large steel manufacturer in India has come to deeply recognize the value of preventing failures before they occur.
The negative impacts of unplanned downtime can often escalate rapidly and unpredictably, evolving into catastrophic events that lead to exponential cost increases. To put this into perspective, a non-catastrophic unplanned event at a large steel plant is estimated to result in daily losses of approximately $23.9 million. If such an event is not resolved promptly or escalates to a catastrophic level, the consequences become even more severe and expand rapidly, affecting areas such as production losses, customer attrition, financial and legal risks, health and safety incidents, regulatory penalties, and emergency repair dispatches. Therefore, avoiding unplanned downtime and mitigating the high risks associated with its occurrence is of paramount importance.
Unplanned downtime is a pain point for all manufacturing sectors, and its cost is particularly high in metal manufacturing. Large steel companies can spend as much as $4 billion annually on maintenance. Currently, approximately 20–25% of maintenance expenses are dedicated to addressing unplanned downtime, equivalent to about $900 million per year. With an appropriate proactive maintenance strategy, a significant portion of these expenses could have been avoided. For example, a large steel manufacturer in India has come to deeply recognize the value of preventing failures before they occur.
The negative impacts of unplanned downtime can often escalate rapidly and unpredictably, evolving into catastrophic events that lead to exponential cost increases. To put this into perspective, a non-catastrophic unplanned event at a large steel plant is estimated to result in daily losses of approximately $23.9 million. If such an event is not resolved promptly or escalates to a catastrophic level, the consequences become even more severe and expand rapidly, affecting areas such as production losses, customer attrition, financial and legal risks, health and safety incidents, regulatory penalties, and emergency repair dispatches. Therefore, avoiding unplanned downtime and mitigating the high risks associated with its occurrence is of paramount importance.
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