Restoring confidence in asset maintenance

THE INDUSTRIAL sector is a powerhouse of energy consumption, responsible for around 37% of global energy use, an increase from 34% just two decades ago, according to the International Energy Agency (IEA).

Yet, many businesses still rely on outdated maintenance practices that put strain on equipment, productivity and energy efficiency. These are risks that organisations can no longer afford, especially in an industry where margins are tight, competition is fierce, and sustainability is non-negotiable.

While outcome-based maintenance offers a smarter, more strategic alternative, asset management shouldn’t stop there. Instead of stumbling around in the dark trying to navigate efficiency challenges, businesses can turn to services like energy appraisals for clear insights into equipment performance, allowing them to make informed, strategic decisions.

Condition-based maintenance in action

A recent survey commissioned by ABB found that 21% of businesses still follow a "run-to-fail" maintenance approach - waiting until equipment breaks down before performing any servicing. While this approach may be enticing because it requires less planning upfront, it ultimately leaves businesses vulnerable to unnecessary costs and energy inefficiency. 80% of companies using this maintenance strategy experience failures at least once a month, and those unplanned outages can cost up to $1m for an eight-hour disruption.

Condition-based maintenance provides a smarter, more strategic alternative by focusing on real performance data and working in line with a business’s goals. Instead of reacting to failures, this approach ensures that maintenance efforts are targeted where and when they’re needed most. As a result, businesses can enjoy improved uptime, optimised energy use, and reduced operational costs, allowing them to focus on what really matters - staying competitive, efficient, and in control of their assets.

Reducing Carbon Emissions with Smarter Maintenance

To ensure peak performance across 24 wind turbines responsible for nearly a quarter of Estonia’s wind energy output, Enefit Green, the largest wind energy producer in the Baltics, sought a smarter approach to maintenance. By partnering with ABB Motion Services, they adopted reconditioning and maintenance strategies that not only improved turbine reliability but also cut carbon emissions by an impressive 80%.  

What worked in the company’s favour was investing in lifecycle extension solutions - a sustainable approach that maximises the value of existing assets instead of replacing equipment on a fixed schedule. Traditional time-based maintenance often leads to unnecessary waste, as fully functional parts get swapped out simply because they’ve reached their prescribed expiry date. By shifting to a condition-based strategy, Enefit Green ensured that only genuinely worn-out components were replaced, allowing them to reduce costs as well as material and energy waste.

Oswald Deuchar is global head of modernization services at ABB Motion Services

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