Proactive Strategies Slash PLC & DCS Maintenance Costs
19 Apr 2025
Industry Shift: 78% of Manufacturers Adopt Predictive Maintenance by 2025
$23B
Predictive Maintenance Market Value by 2027 (25% CAGR)
63%
Reduction in Maintenance Costs for Early Adopters
Real-World Results
- ✅ 82% asset availability improvement at BMW Leipzig Plant
- ✅ 41% fewer compressor failures in oil & gas facilities
- ✅ $2.7M annual savings for PepsiCo bottling lines
- ✅ 57% faster fault resolution in pharmaceutical cleanrooms
Sensor Revolution
0.1°C
Temperature monitoring precision
99.3%
Sensor data transmission reliability
±0.5%
Current measurement accuracy
Maintenance Metrics Transformed
94%
Predictive accuracy for motor failures
28min
Average alert-to-action time
12x
ROI over 3-year period
Industry Benchmarks
Top Performers Achieve:
• 93.4% OEE (vs industry average 76.2%)
• $0.38/hr maintenance cost per machine
Lagging Plants Report:
• 14.2% unplanned downtime
• $18.50/hr emergency repair costs
| Model | Title | Link |
|---|---|---|
| 330901-00-30-10-02-00 | 3300 NSV Proximity Probes | Learn More |
| 330980-50-CN | 3300 XL NSV Proximitor Sensor | Learn More |
| 990-04-XX-01-00 MOD 147202-01 | Vibration Transmitter | Learn More |
| 990-04-XX-01-CN MOD 165335-01 | Vibration Transmitter System | Learn More |
| 990-05-XX-01-00 MOD 165335-01 | Advanced Vibration Transmitter | Learn More |
| 21000-28-10-30-066-04-02 | Bently Nevada Monitoring System | Learn More |
| 21000-28-05-20-065-03-02 | Proximity Probe Housing Assembly | Learn More |
| 21000-28-10-30-050-03-02 | Industrial Proximity Sensor | Learn More |
| 21000-28-10-15-050-04-02 | Precision Probe Assembly | Learn More |
| 21000-28-10-30-095-03-02 | High-Performance Proximity Probe | Learn More |
| 21000-28-10-15-095-04-02 | Compact Proximity Detection System | Learn More |
| 135473-01 | Keyphasor I/O Module | Learn More |
| 135489-04 | Bently Nevada I/O Module | Learn More |
| 991-01-XX-01-00 MOD 288865-01 | Thrust Position Transmitter | Learn More |