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35 of the most interesting statistics about maintenance and facility management

Watching trends in data is key to planning for the future, whether at an individual level or in facility management as a whole. The following statistics should give you a clear idea of what the future holds for maintenance and facilities management.

Budgeting and Spend

  1. Between 2004 and 2008, the U.S. spent about 57% of its transportation infrastructure budget on new construction projects. The 43% leftover was spent on maintaining the 98.7% of roads remaining.
  2. The U.S. has over 47,000 bridges that are considered to be in urgent need of repairs, while 38% of all America’s bridges need some form of repair work. It would take about 80 years to complete it all.
  3. The global market for enterprise asset management software is valued at $4 billion, and it’s expected to grow at a CAGR of 11% per year. At that rate, its value will have doubled to $8 billion by 2022.
  4. As of 2018, about 53% of facilities use a CMMS to monitor their maintenance. Additionally, 55% use spreadsheets and schedules, and 44% still use paper.

CMMS and Software Adoption

  1. In 2017, 78% of companies who used a CMMS to manage their assets reported seeing improvements in equipment life.
  2. Up to 80% of all attempted CMMS implementations fail.
  3. Perhaps coincidentally, about 80% of all CMMS users don’t use all the functions offered by the software.
  4. For one company in 2017, data visualization software reduced production hours by 320 hours while also increasing production by 15%.

Maintenance Career Outlook

  1. The U.S. employs a total of over 80,000 machinery maintenance workers.
  2. The nation also has over 131,000 aircraft service technicians and mechanics.
  3. About 1.3 million people currently work as general maintenance workers, with 302,000 working in the real estate sector.
  4. The job outlook for maintenance professionals is projected to grow at about 8% over the next ten years.
  5. The average salary for a maintenance technician in 2019 is just under $39,000 per year.
  6. The top paying industry for machinery maintenance workers is the Federal executive branch at $72,350 per year as of 2019, followed closely by motor vehicle manufacturing at $71,330.

Downtime

  1. About 44% of all unscheduled equipment downtimes result from aging equipment, making it the leading cause of unscheduled downtime.
  2. Unplanned downtimes cost an estimated $50 billion every year.
  3. Overall, downtime costs most factories somewhere between 5% and 20% of their productive capacity.

Safety

  1. Poor compliance with lockout/tagout standards ranked number five in OSHA’s most frequently cited violations in 2018.
  2. Up to 30% of all manufacturing deaths are related to a maintenance activity.
  3. Companies can save between 12% and 18% by using preventive maintenance over reactive, and each dollar spent on PM saves an average of $5 later on.
  4. Factories throughout the U.S. are estimated to be using about $40 billion worth of outdated equipment.

Internet of Things (IoT)

  1. As of 2017, about 53% of companies adopted big data analytics, which includes predictive maintenance and IIoT technologies.
  2. By 2024, IIoT technologies are predicted to help create nearly $800 billion in economic value.
  3. Roughly 30% of all manufacturers have difficulty understanding IoT.
  4. Even so, as of 2018 nearly half of all manufacturers are placing greater emphasis on IIoT technologies.
  5. Worldwide spending on IoT technology is estimated to reach $1.2 trillion in 2022 with a CAGR of 13.6%.
  6. The number of connected devices in use worldwide is estimated to be over 17 billion, with 7 billion IoT devices.

Predictive Maintenance

  1. The overall use of predictive maintenance rose from 47% in 2017 to 51% in 2018, though preventive maintenance is still preferred by 80% of maintenance personnel.
  2. 80% of manufacturing plants use preventive maintenance, and over half use predictive maintenance with analytical tools.
  3. In 2012, the U.S. Bureau of Labor Statistics estimated that the nation would be short 10 million workers over the course of the following six years.
  4. Roughly 10% (and maybe even less) of industrial equipment ever actually wears out, meaning a very large portion of mechanical failures are avoidable.
  5. Predictive analytics yields a tenfold return on investment, and it results in a savings of 30% to 40%.
  6. As of 2018, the most common challenge facilities face is lack of resources, including human, technical, and strategic resources. The number of facilities who considered this a challenge was 49%.
  7. Historically, total productive maintenance has been shown to increase plant capacity by over 10% and productivity by 50%, but over half of all attempts to implement TPM result in failure.
  8. 79% of businesses see predictive maintenance as the main application of industrial data analytics.