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
- 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.
- 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.
- 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.
- 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
- In 2017, 78% of companies who used a CMMS to manage their assets reported seeing improvements in equipment life.
- Up to 80% of all attempted CMMS implementations fail.
- Perhaps coincidentally, about 80% of all CMMS users don’t use all the functions offered by the software.
- For one company in 2017, data visualization software reduced production hours by 320 hours while also increasing production by 15%.
Maintenance Career Outlook
- The U.S. employs a total of over 80,000 machinery maintenance workers.
- The nation also has over 131,000 aircraft service technicians and mechanics.
- About 1.3 million people currently work as general maintenance workers, with 302,000 working in the real estate sector.
- The job outlook for maintenance professionals is projected to grow at about 8% over the next ten years.
- The average salary for a maintenance technician in 2019 is just under $39,000 per year.
- 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.
- About 44% of all unscheduled equipment downtimes result from aging equipment, making it the leading cause of unscheduled downtime.
- Unplanned downtimes cost an estimated $50 billion every year.
- Overall, downtime costs most factories somewhere between 5% and 20% of their productive capacity.
- Poor compliance with lockout/tagout standards ranked number five in OSHA’s most frequently cited violations in 2018.
- Up to 30% of all manufacturing deaths are related to a maintenance activity.
- 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.
- Factories throughout the U.S. are estimated to be using about $40 billion worth of outdated equipment.
Internet of Things (IoT)
- As of 2017, about 53% of companies adopted big data analytics, which includes predictive maintenance and IIoT technologies.
- By 2024, IIoT technologies are predicted to help create nearly $800 billion in economic value.
- Roughly 30% of all manufacturers have difficulty understanding IoT.
- Even so, as of 2018 nearly half of all manufacturers are placing greater emphasis on IIoT technologies.
- Worldwide spending on IoT technology is estimated to reach $1.2 trillion in 2022 with a CAGR of 13.6%.
- The number of connected devices in use worldwide is estimated to be over 17 billion, with 7 billion IoT devices.
- 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.
- 80% of manufacturing plants use preventive maintenance, and over half use predictive maintenance with analytical tools.
- 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.
- Roughly 10% (and maybe even less) of industrial equipment ever actually wears out, meaning a very large portion of mechanical failures are avoidable.
- Predictive analytics yields a tenfold return on investment, and it results in a savings of 30% to 40%.
- 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%.
- 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.
- 79% of businesses see predictive maintenance as the main application of industrial data analytics.