Manufacturing: Predictive Maintenance & AI — The Cost of Downtime vs. the Cost of AI
The numbers reveal where the real savings are hiding — and how fast a predictive maintenance program can pay for itself.
What’s inside:
- What unplanned downtime really costs, by the hour and by the plant
- The root causes behind most production stops
- Downtime cost, before and after predictive maintenance
- The ROI numbers behind AI-powered maintenance programs.
Download your free copy of the Predictive Maintenance & AI infographic.
Whay Downtime Actually Cost
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$852M/wk
Upper-bound cost of unplanned downtime across the global manufacturing sector, every week.
Fluke Corporation, Oct 2025 survey
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61%
Of manufacturers suffered at least one unplanned downtime event in the past 12 months.
Fluke Corporation, Oct 2025 survey
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$42.6M
Potential loss from a single outage stretching to 72 hours — 15% of manufacturers report incidents this long.
Fluke Corporation, Oct 2025 survey
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$1.4T/yr
Lost annually by the Fortune Global 500 to unplanned downtime — about 11% of total revenue, still the benchmark cited across 2025–2026 industry reports.
Siemens, True Cost of Downtime, ref. 2025–2026 reporting
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800hrs/yr
Production time the average factory burns annually on breakdowns that were, in hindsight, predictable.
OxMaint, State of Manufacturing Maintenance 2025–2026
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31%
Of maintenance and operations managers say downtime costs rose again in 2025, mainly on parts inflation.
MaintainX, 2025 State of Industrial Maintenance
