Explore Predictive Maintenance with Hexagon EAM’s AI Tools

For manufacturers, a single unexpected machine failure can cascade into costly downtime, disrupted schedules, and frustrated customers. But what if you could see potential breakdowns coming—and stop them before they happen? Predictive maintenance powered by Hexagon EAM’s AI-driven tools is revolutionizing how manufacturers approach maintenance, delivering reliability, efficiency, and cost savings.

The High Cost of Machine Downtime

The numbers don’t lie. Machine downtime is one of the most expensive challenges manufacturers face. Here are some real-world estimates to highlight the financial impact:

• Average Hourly Loss Across Industries: Downtime costs average $5,600 per minute, translating to $336,000 per hour.
• Automotive Manufacturing: A single hour of downtime can cost $1 million or more, especially in high-volume operations.
• Food and Beverage Processing: Equipment failure during peak production hours can lead to spoilage, costing $30,000 to $50,000 per hour.
• Oil and Gas Production: In this sector, downtime can skyrocket to $1.5 million per day.

These costs include lost productivity, delayed orders, labor expenses, overtime for recovery, and damage to customer relationships. Even smaller-scale disruptions can add up to hundreds of thousands of dollars in losses over time.

Predictive Maintenance in Action

Predictive maintenance is a proactive approach that uses data and analytics to predict and prevent equipment failures before they occur. Here’s how it works in real-world scenarios:

• Automotive Manufacturing: A robotic arm on an assembly line begins to show signs of slower-than-usual movements. Sensors track vibration levels, which indicate that the motor bearings are starting to degrade. Predictive maintenance schedules the replacement of the motor during the next planned maintenance window, avoiding a breakdown that could cost $1 million in downtime.
• Food and Beverage Processing: A packaging line conveyor starts exhibiting temperature spikes in its drive system. The AI system identifies that the spikes align with early-stage gear wear. Maintenance teams replace the gears during off-peak hours, ensuring minimal impact on operations and avoiding potential downtime costs of $40,000 per hour.
• Aerospace Parts Production: A milling machine shows an increase in spindle vibration beyond safe thresholds. Predictive analytics suggest imminent bearing failure. Rather than waiting for a catastrophic failure that could lead to $150,000 in repairs and lost production, the bearings are replaced during scheduled downtime.

How Hexagon EAM AI Tools Enhance Predictive Maintenance

Hexagon EAM (Enterprise Asset Management) takes predictive maintenance to the next level with AI-driven insights.

Here’s how:

• Real-Time Monitoring: Continuously tracks machine health through sensor data, identifying performance trends and abnormalities.
• Data-Driven Predictions: Uses AI to forecast potential breakdowns by analyzing historical failure patterns and environmental conditions.
• Automated Alerts: Sends notifications to maintenance teams when issues are detected, allowing for swift and strategic planning.
• Resource Optimization: Schedules maintenance during non-peak hours, minimizing disruptions and reducing overtime costs.

The Long-Term Payoff

The ROI of predictive maintenance grows exponentially over time. As AI tools gather more data, their accuracy improves, further reducing downtime and extending equipment lifespans. Preventative measures also reduce the need for costly spare parts inventories and enable leaner operations.

For example, consider an industrial air compressor running 24/7. Without predictive maintenance, the compressor might fail suddenly, halting production for hours and leading to $250,000 in downtime costs. With predictive maintenance, sensors detect a subtle increase in motor temperature—a sign of impending failure. The issue is resolved during scheduled downtime, saving the manufacturer from an expensive and disruptive event.

Why Manufacturers Should Act Now

As industrial equipment grows more complex, the cost of downtime is only going to rise. Manufacturers need solutions that offer visibility, precision, and adaptability. With Hexagon EAM’s cutting-edge AI tools, you’re not just maintaining machines—you’re building resilience and reliability into your operations.

Ready to Future-Proof Your Maintenance?

Predictive maintenance powered by AI is no longer a luxury—it’s a necessity for manufacturers looking to stay competitive. By investing in solutions like Hexagon EAM, you can reduce downtime, cut costs, and boost productivity.

Start predicting your future today—because when it comes to maintenance, being proactive always wins over being reactive.

Contact Us >