Study details bottom-line impact of unplanned downtime

Despite growing awareness, the data highlights that 44% of leaders experience equipment-related interruptions at least monthly, with 14% reporting stoppages every single week – implying major financial and operational risks. The majority estimate these sudden disruptions cost anywhere from $10,000 up to $500,000 per hour. For 7% the figure climbs even higher.

The report reveals key gaps between planning and execution. While 55%of industry players claim to have a proactive moderniaation strategy, only one in five of those grappling with weekly interruptions actually implement such a plan. Likewise, among the 30% who are dealing with monthly issues, just one third (34%) actively manage life-cycle processes for their facilities and assets.

“Unplanned downtime is costing industry up to half a million dollars per hour – yet one in three businesses hasn’t modernised their motor-driven systems in the last two years. That’s more than a missed opportunity, it’s a silent crisis,” comments Oswald Deuchar, Global Head of Modernisation Program, ABB Motion Services. “Our research shows that those who shift from reactive firefighting to forward-looking life-cycle strategies experience fewer failures and greater resilience. A key challenge, though, remains in justifying the up-front investment. With some applications, upgrading obsolete, inefficient equipment can generate return on investment in less than two years, but leadership buy-in is often hard-won.”

Communication gaps remain. Despite the strikingly high hourly cost of unplanned downtime, over a third of respondents find it somewhat difficult or very difficult to articulate the return on investment (ROI) of modernisation projects to senior leaders. Meanwhile, 17% of businesses “rarely or never” include the impact of lost productivity in their capital investment decisions.

Cost remains the top barrier to modernisation for 28% of industrial players. Among the 66% who have undertaken an upgrading and retrofitting project in the last two years, just over one quarter explicitly did so to reduce stoppage risks – highlighting that the link between continuous life-cycle management and operational reliability is still not fully understood or acted upon, even by many modernisation proponents.

“We’re hoping this report opens some eyes. Modernisation isn’t just about replacing old parts, it’s about rethinking performance. With 44% of industrial players facing monthly setbacks, the case for smarter asset management has never been more urgent,” continues Deuchar. “ABB’s approach combines digital intelligence, modular retrofits, and circularity principles to turn yesterday’s equipment into tomorrow’s high performers. This is how we enable clients to trade last-minute fixes for long-term foresight. Because today uptime is a mandate for a more competitive future.”

Read the full report here