Unplanned Downtime
12/9/25
|
Sahil Patel
Factories slow down one fix at a time, as every change depends on an external integrator. The financial damage is staggering: unplanned downtime now costs leading manufacturers up to $1.4 trillion yearly—11% of revenues—while a single hour out in automotive runs $2.3 million (Siemens 2024).
Flexible, orchestrated automation is the only path forward, but years of custom code, vendor lock-in, and talent gaps hold factories back.
Industry Stats (Siemens 2024)
Automotive downtime: $2.3 million per hour—up 113% since 2019.
Fortune 500 industrials: $1.4 trillion lost annually to downtime (11% of all revenues).
Heavy industry: $59 million annual downtime cost per plant, quadruple since 2019.
Average large plant: 25 downtime incidents per month (down from 42 in 2019, thanks to Predictive Maintenance).
Nearly 50% of firms now staff dedicated Predictive Maintenance (PdM) teams, up from a quarter five years ago.
Full PdM and digital orchestration could save 2.1 million downtime hours, $388 billion in productivity, and $233 billion in annual maintenance costs.
What Manufacturers Can Do: The Conduit Approach
Break Out of Integrator Dependency:
Conduit delivers advanced automation in weeks—ending the cycle of expensive custom code and slow deployments.
Unify Your Systems Seamlessly:
With Conduit's hardware-agnostic platform, factories connect robots, machines, sensors, and PLCs—across brands—without re-integrating for every change. One pane of glass; one source of truth.
Enable Operator-Led Innovation:
Conduit's no-code workflow automation lets operators and engineers orchestrate robots and machines themselves, cutting response and recovery times. No longer are teams reliant on outside hourly support just to fix basics.
Actionable Monitoring and Analytics:
Conduit's AI Analytics Studio brings live data, machine traceability, and instant performance dashboards—helping you identify downtime causes and eliminate waste, without vendor bottlenecks.
Always-On Expertise:
A dedicated Conduit Forward Deployed Engineer (FDE) partners with your team—on site, on call—troubleshooting, optimizing, and ensuring autonomous, resilient automation. We deliver outcome-driven service, not just another in-and-out project, and we don't charge typical hourly integrator fees.
Downtime is costing more than revenue—it’s costing manufacturers their innovation edge. The answer isn’t another integrator contract, but a team and technology built to keep you in control.
Conduit was founded so manufacturers can orchestrate automation at their own speed—with the tools, services, and real-time data that make downtime a thing of the past.
The next leap in manufacturing starts with a solution built for your floor, your people, and your growth.
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