CMMS Statistics 2024 – Everything You Need to Know

• According to maintenance professionals, the leading causes of unscheduled equipment downtime are aging equipment (34%), mechanical failure (20%), operator error (11%), lack of time for maintenance (9%), and poor equipment design (8%). ^[1]
• Roughly10% of industrial equipment ever actually wears out, meaning a very large portion of mechanical failures are avoidable. ^[2]
• Historically, total productive maintenance has been shown toincrease plant capacity by over 10%and productivity by 50%, but over half of all attempts to implement TPM result in failure. ^[2]

CMMS Adoption Statistics

• The top challenges encountered by maintenance teams have to do with hiring, onboarding, and retaining people (48%), streamlining processes (27%), and successful technology adoption (25%). ^[1]

CMMS Latest Statistics

• What is also important to mention is that we were only looking at statistics that came out in the last 3 years and that 90% of data in this infographic is from 2018. ^[4]
• According to the Plant Engineering 2017 Maintenance Study , which was one of our main sources for this infographic, the average time spent on scheduled maintenance is 19 hours per week. ^[4]
• Among the facilities that do actively use a maintenance strategy, 78% of them are turning to preventive maintenance statistics and 61% said that they also still rely on reactive maintenance as a whole. ^[4]
• CMMS is used in 59% of those cases followed by predictive maintenance and reliability centered maintenance with 48% and 29% respectively. ^[4]
• The last thing we want to mention here is that 37% of respondents are looking at maintenance as a profit center in contrast to 22% of people that look at maintenance strictly as a cost center. ^[4]
• Reports show that only 9% of them fully integrated mobile devices as a part of their CMMS and IIoT systems. ^[4]
• What is also interesting is that a third of the respondents said how they do not have any plans to introduce mobile devices into their maintenance management while 27% of them are at least considering investing in this area. ^[4]
• However, 21% believe it will have no impact and 25% said they do not know. ^[4]
• In the same survey, 37% of respondents said that they do plan to increase the investment into CMMS / EAM. ^[4]
• Another thing we noticed is that a majority (84%). ^[4]
• The sweet spot seems to be 50$ 100$ with 34% of firms looking for that price range. ^[4]
• As of that time, 65 percent of the respondents indicated that CMMS helps improve the overall efficiency of plant manufacturing. ^[5]
• Available to download in PNG, PDF, XLS format 33% off until Jun 30th. ^[5]
• It is projected to register a value of $701.3 billion by 2026, growing at a CAGR of about 2.19%. ^[1]
• In 2020, 46.91% of surveyed companies in North America reported that they spent 21% to 40% of their operating budget on the cleaning and maintenance of their equipment and supplies. ^[1]
• Meanwhile, 35.67% spent 1% to 20% of their budget. ^[1]
• On the other hand, 2.25% of companies spent more than 80% of their operating budget on equipment maintenance alone. ^[1]
• Meanwhile, 18% of companies spend 40 hours or more per week on maintenance. ^[1]
• Around 66% of maintenance teams say their budget is either staying the same or increasing in 2021. ^[1]
• Meanwhile, 60% of manufacturing companies still performed reactive maintenance. ^[1]
• In 2020, the majority of facility management companies (90.61%). ^[1]
• On the other hand, 51% sought the services of distributors and vendors, while 24.86% opted for online training providers. ^[1]
• Only 16.02% enlisted a thirdparty, industry. ^[1]
• In all, 66% of maintenance professionals from various industries say they use CMMS to track their maintenance program, a 24% increase from 2019. ^[1]
• 74% of CMMS users believe that this tool improves productivity, while 58% consider it cost. ^[1]
• Furthermore, 57% of users see its ease of use as an advantage. ^[1]
• Moreover, 51% of CMMS users think that the tool helps reduce downtime. ^[1]
• Moreover, 32% of maintenance executives believe that IoT will help them better understand machine health, while 27% think it can help them better predict and prevent equipment shutdowns. ^[1]
• Another 25% believe IoT will change the way their maintenance personnel work and interact with all levels of their operation. ^[1]
• It is estimated that industrial IoT will generate around $800 billion in economic value by 2024. ^[1]
• In relation to this, the global discrete manufacturing industry was already projected to spend $119 billion in IoT in 2019, while the process manufacturing industry was estimated to spend $78 billion. ^[1]
• As such, 47% of manufacturing companies and teams still use in house spreadsheets for maintenance schedules, while 46% utilize clipboards and paper records of maintenance rounds. ^[1]
• About 30% of maintenance professionals say they do not use handheld or mobile devices for maintenance tasks, and that they have no plans of using them in the future. ^[1]
• 25% of maintenance leaders think IoT will have no impact on their operations. ^[1]
• The real estate and leasing industry hired the most maintenance and repair workers in the US in 2019 at 22%. ^[1]
• It is followed by manufacturing (13%), government (12%), educational services (8%), and healthcare and social assistance (8%). ^[1]
• The employment rate for general maintenance and repair workers in the US is expected to grow by 4% come 2029. ^[1]
• The average annual salary of maintenance workers in the state is $52,913, with the highest 10% earning around $73,000 and the lowest 10% receiving about $38,000 per year. ^[1]
• The latest US jobs data also shows an unemployment rate of 2.3% among maintenance and repair workers. ^[1]
• Between 2004 and 2008,the U.S. spent about 57% of its transportation infrastructure budgeton new construction projects. ^[2]
• The 43% leftover was spent on maintaining the 98.7% of roads remaining. ^[2]
• The U.S. has over47,000 bridgesthat are considered to be in urgent need of repairs, while 38% of all America’s bridges need some form of repair work. ^[2]
• As of 2018, about53% of facilities use a CMMSto monitor their maintenance. ^[2]
• Additionally, 55% use spreadsheets and schedules, and 44% still use paper. ^[2]
• In 2017, 78% of companies who used a CMMS to manage their assets reported seeing improvements in equipment life. ^[2]
• Up to80% of all attempted CMMS implementations fail. ^[2]
• The job outlook for maintenance professionals is projected to grow atabout 8%over the next ten years. ^[2]
• About 44% of all unscheduled equipment downtimesresult from aging equipment, making it the leading cause of unscheduled downtime. ^[2]
• Unplanned downtimes cost an estimated$50 billion every year. ^[2]
• Overall, downtime costs most factories somewhere between5% and 20%of their productive capacity. ^[2]
• to30% of all manufacturing deathsare related to a maintenance activity. ^[2]
• Companies can save between12% and 18%by using preventive maintenance over reactive, and each dollar spent on PM saves an average of $5 later on. ^[2]
• Factories throughout the U.S. are estimated to be using about$40 billion worthof outdated equipment. ^[2]
• As of 2017,about 53% of companiesadopted big data analytics, which includes predictive maintenance and IIoT technologies. ^[2]
• By 2024, IIoT technologies are predicted to help createnearly $800 billionin economic value. ^[2]
• Roughly 30%of all manufacturers have difficulty understanding IoT. ^[2]
• Worldwide spending on IoT technology is estimated to reach$1.2 trillion in 2024with a CAGR of 13.6%. ^[2]
• The number of connected devices in use worldwide is estimated to beover 17 billion, with 7 billion IoT devices. ^[2]
• The overall use of predictive maintenance rose from47% in 2017 to 51% in 2018, though preventive maintenance is still preferred by 80% of maintenance personnel. ^[2]
• 80% of manufacturing plantsuse preventive maintenance, and over half usepredictive maintenancewith analytical tools. ^[2]
• In 2012, the U.S. Bureau of Labor Statistics estimated that the nation would beshort 10 million workersover the course of the following six years. ^[2]
• Predictive analytics yields atenfold returnon investment, and it results in a savings of 30% to 40%. ^[2]
• The number of facilities whoconsidered this a challenge was 49%. ^[2]
• 79% of businessessee predictive maintenance as the main application of industrial data analytics. ^[2]
• The 80/20 rule is a great reference because 80 percent of your maintenance activities should be proactive, while 20 percent should be for unplanned maintenance items. ^[6]
• A company can save between 12 to 18 percent using preventive maintenance over reactive maintenance. ^[6]
• Facilities implementing proper HVAC maintenance will use 15 to 20 percent less energy. ^[6]
• Commissioning can save a typical 100,000square foot hotel 10 to 15 percent of its energy costs or roughly $20,000 per year. ^[6]
• Buildings in the United States were responsible for 39 percent of U.S energy consumption in 2005. ^[6]
• Of that total, commercial buildings accounted for 46.3 percent. ^[6]
• Eighty percent of employees waste an average of 30 minutes per day retrieving information. ^[6]
• Professionals spend 5 to 15 percent reading information but up to 50 percent looking for it. ^[6]
• A famous study by Albert Mehrabian found that nonverbal language makes up 55 percent of how we communicate in faceto. ^[6]
• He also concluded that we communicate as much as 38 percent of our message through our voice , with as little as 7 percent through the words we actually say. ^[6]
• Understanding and recognizing the signs and signals that make up this 55 percent can help you when you communicate with others. ^[6]
• The 80/20 rule is a great reference because 80 percent of your maintenance activities should be proactive, while 20 percent should be doing unplanned maintenance items. ^[7]
• Preventive Maintenance a company can save between 1218% using preventive maintenance over reactive maintenance Facilities implementing proper HVAC maintenance will use 15. ^[7]
• Commissioning can save a typical 100,000ft 2 hotel 10 15% of its energy costs or roughly $20,000 per year Buildings in the U.S. are responsible for 39% of U.S energy consumption in 2005 and of that total commercial buildings accounted for 46.3%. ^[7]
• 80% of employees waste an average of 30 minutes per day retrieving information Professionals spend 5 15% reading information but up to 50% looking for it. ^[7]
• 39% percent of facilities use CMMS to manage maintenance activities. ^[3]
• A study by UpKeep found that only 39% of maintenance managers are utilizing CMMS. ^[3]
• So what’s stopping the other 61%?. ^[3]
• This fear isn’t always unfounded — in our 2018 survey, we found that of the buyers questioned, three percent were looking to downsize from a CMMS that was too cumbersome. ^[3]
• According to the Pew Research Center, in 2017, 77% of all U.S. adults owned a smartphone and 92% of 18 29 year olds owned the same. ^[8]
• Increase work flow efficiency by 50% with Hippo Mobile Schedule a free demo. ^[8]
• Some experts estimate 80 percent of plant maintenance management system implementations fail. ^[9]
• Approximately 90 percent of plant maintenance managers say they are not using their CMMS at its maximum capability, according to a Reliable Plant survey conducted by educator Kris Bagadia. ^[9]
• Most MaintainX clients experience a first year ROI ranging from 25 to 300 percent. ^[9]
• **Save 17 percent on any package by choosing the annual option. ^[9]
• MaintainX offers a 100 percent free CMMS solution while also offering solutions with additional functionality through our paid plans. ^[9]
• Ask yourself Do I want to be one of the approximately 70% of all CMMS implementations that fail?. ^[10]
• In 2016, the average cost of downtime across all businesses was $260,000 per hour—a 60% jump from 2014, according toAberdeen Research. ^[11]
• Consultants believe that 80% of industrial facilities are unable to accurately estimate their downtime. ^[11]
• A common estimate is that factories lose anywhere from 5% to 20% of their productivity due to downtime. ^[11]
• Human error causes 23% of unplanned downtime in manufacturing— 2.5x higher than other sectors, according toServiceMax. ^[11]
• A 2017 ServiceMax survey found that 70% of companies lack complete awareness of when equipment is due for maintenance or upgrade. ^[11]
• IBM reports that a survey of asset managers found that 75% cite system reliability as the main reason to invest in EAM. ^[12]
• According to IBM, PDF , it “allows organizations to test out new approaches and offerings for their asset intensive businesses and find new insights and operating models for competitive advantage.”. ^[12]

I know you want to use CMMS Software, thus we made this list of best CMMS Software. We also wrote about how to learn CMMS Software and how to install CMMS Software. Recently we wrote how to uninstall CMMS Software for newbie users. Don’t forgot to check latest CMMS statistics of 2024.

Reference

1. smglobal – https://www.smglobal.com/blog/maintenance-software-business-case/.
2. financesonline – https://financesonline.com/maintenance-statistics/.
3. upkeep – https://www.upkeep.com/blog/35-of-the-most-interesting-statistics-about-maintenance-and-facility-management.
4. selecthub – https://www.selecthub.com/cmms/cmms-buying-trends/.
5. limblecmms – https://limblecmms.com/blog/cmms-maintenance-statistics/.
6. statista – https://www.statista.com/statistics/778148/us-cmms-advantage-manufacturing-industries/.
7. reliableplant – https://www.reliableplant.com/Read/30192/why-need-cmms.
8. transcendent – https://transcendent.ai/blog/asset-management/42-roi-statistics-that-prove-you-need-a-maintenance-management-system/.
9. iofficecorp – https://hippocmms.iofficecorp.com/blog/mobile-cmms-software-benefits.
10. getmaintainx – https://www.getmaintainx.com/blog/what-is-cmms/.
11. fiixsoftware – https://www.fiixsoftware.com/blog/do-i-really-need-training-for-my-cmms/.
12. automationworld – https://www.automationworld.com/factory/plant-maintenance/article/21722807/connecting-maintenance-finance-and-safety.
13. ibm – https://www.ibm.com/topics/what-is-a-cmms.

How Useful is Cmms

One of the biggest advantages of CMMS is its ability to streamline maintenance processes and improve operational efficiency. By centralizing all maintenance-related data and tasks in one system, CMMS help organizations maintain better control over their assets and equipment. This makes it easier for maintenance teams to identify and address issues before they escalate, ultimately reducing downtime and increasing equipment reliability.

Furthermore, CMMS can help organizations optimize their maintenance strategies by providing real-time insights into equipment performance and history. This data-driven approach allows maintenance teams to make more informed decisions about when and how to conduct maintenance activities, leading to cost savings and improved asset longevity.

Another key benefit of CMMS is its role in enhancing compliance and accountability within organizations. By enabling maintenance teams to track all maintenance activities in a systematic manner, CMMS help ensure that industry regulations and standards are being met. Additionally, the audit trail capabilities of CMMS provide a transparent record of all maintenance activities, which can be invaluable in demonstrating regulatory compliance or identifying areas for improvement.

Furthermore, CMMS can also play a critical role in inventory management by tracking spare parts and materials used in maintenance activities. By maintaining accurate records of inventory levels and usage, organizations can prevent stockouts, reduce excess inventory, and increase overall efficiency in managing maintenance supply chain.

In addition to these benefits, CMMS also offer various tools and features that can further enhance maintenance operations. For example, predictive maintenance capabilities within CMMS can help organizations move from reactive to proactive maintenance strategies, by predicting equipment failure before it occurs. Furthermore, mobile access to CMMS enables maintenance teams to access critical information and updates in real-time, regardless of their location. This can be particularly useful for organizations with remote or distributed maintenance teams.

However, it is important to note that while CMMS have many benefits, their usefulness ultimately depends on how well they are implemented and utilized within an organization. Simply purchasing a CMMS system is not enough – organizations must also invest in proper training for employees, ensure data quality and accuracy, and regularly update and customize the system to meet evolving maintenance needs.

In conclusion, CMMS can indeed be a highly useful tool for organizations looking to improve maintenance operations, increase efficiency, and drive cost savings. However, to truly maximize the benefits of CMMS, organizations must commit to leveraging the system effectively and consistently. By doing so, they can unlock the full potential of CMMS and transform maintenance operations for the better.

In Conclusion

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