Predictive Maintenance Market Size, Share & Trends Analysis Report By Component (Solution, Services), By Techniques (Power System Assessments, Infrared thermography, Temperature Monitoring, Fluid Analysis, Circuit Monitor Analysis, Vibration Monitoring), By Deployment (On-Premises, Cloud), By Organization Size (Small and Middle Enterprises (SMEs), Large Enterprises), By End-User (Manufacturing, Government, Transportation, Energy and Utilities, Healthcare, Aerospace and Defense) and By Region(North America, Europe, APAC, Middle East and Africa, LATAM) Forecasts, 2024-2032

Predictive Maintenance Market Size

The global predictive maintenance market size was valued at USD 7.5 billion in 2023 and is projected to reach from USD 9.8 billion in 2024 to USD 88.8 billion by 2032, registering a CAGR of 31.6% during the forecast period (2024-2032).

The increasing use of machine-to-machine (M2M) communication, increased investment in extending the lifespan of various aging industrial machinery, and rising integration with remote monitoring to conduct advanced inspections are key factors driving the Predictive Maintenance Market share.

Predictive maintenance (PdM) is an advanced maintenance technique that uses data analytics, machine learning, and sensor technologies to forecast when equipment may fail, allowing repair to be conducted proactively before the failure occurs.

At the moment, one of the fundamental reasons positively influencing the market is the growing demand for predictive maintenance as operations of various industrial assets become more automated. Aside from that, the increasing use of machine-to-machine (M2M) connectivity and cloud technology to study a wide range of data collected from industrial and business assets provides a promising industry view. In addition, professionals are increasingly using predictive maintenance to anticipate and prepare for repairs by using suitable procedures. The increasing use of predictive maintenance to avoid disruptions in production cycles and unnecessary downtime fuels market expansion. 

Aside from this, organizations are increasingly using predictive maintenance to produce a concrete return on investment. Increased investment in extending the life of various old industrial machines drives market expansion. Furthermore, the increasing integration of predictive maintenance with remote monitoring to perform advanced inspections and predict component and equipment failures is driving market expansion. Furthermore, the growing use of predictive maintenance in the healthcare industry to improve the dependability of healthcare infrastructure is driving market expansion.

Highlights

• Solution accounts for the highest revenue share by component.
• Vibration monitoring influenced market growth through various techniques.
• On-premises generates the highest revenue share by deployment.
• Large Enterprises dominate the market by organization size.
• Manufacturing led the market by vertical.

Predictive Maintenance Market Growth Factors

Significant Cost Reduction

Predictive maintenance identifies possible equipment failures before they occur, allowing businesses to arrange maintenance during planned downtime or low-production periods. This reduces unplanned downtime, which is particularly expensive in businesses such as manufacturing, where downtime can result in considerable revenue losses. According to a 2023 Siemens analysis, unplanned downtime costs Fortune 500 firms 11% of their annual revenue, or over USD 1.5 trillion. A Kimberlite study discovered that a 1% downtime rate of 3.65 days costs more than USD 5 million annually.

Furthermore, firms can avoid expensive emergency repairs by proactively resolving concerns identified by predictive maintenance. Emergency repairs may necessitate expedited shipping of parts, overtime compensation for maintenance personnel, and production stoppages, which increase maintenance costs.

• For example, Deloitte research discovered that unscheduled maintenance costs are up to three times more than planned maintenance.

Furthermore, predictive maintenance aids in the optimization of maintenance schedules by prioritizing maintenance tasks based on the actual state of the equipment rather than fixed time intervals. This guarantees that maintenance resources are utilized properly, resulting in fewer unwanted maintenance activities and expenses. According to McKinsey's research, predictive maintenance can reduce maintenance expenditures by up to 40% while increasing equipment uptime by 10% to 20%. As a result, by utilizing predictive maintenance technology and tactics, organizations can realize significant cost savings while enhancing equipment dependability, productivity, and operational efficiency.

Restraining Factors

Complexity of Implementation

Implementing predictive maintenance systems can be difficult, requiring skill in data analytics, machine learning, and domain understanding of the equipment and processes involved. Integrating predictive maintenance solutions into existing enterprise systems, such as asset management or enterprise resource planning (ERP), can sometimes be difficult. The complexity of implementation may dissuade enterprises from adopting predictive maintenance or cause delays in realizing its benefits.

Predictive maintenance is based on integrating data from multiple sources, such as sensors, equipment databases, maintenance records, and external data sources. Data integration can be difficult, especially for firms with fragmented systems and outdated connectivity equipment. Ensuring data quality, consistency, and compatibility across several data sources is critical for the accuracy and reliability of predictive maintenance models.

Furthermore, McKinsey research shows that just 30% of predictive maintenance programs meet their objectives due to data quality, system integration, and organizational preparation issues. This demonstrates the complexities of implementing predictive maintenance and the importance of proper planning and implementation. 

Market Opportunities

Industry 4.0 and Digital Transformation

Industry 4.0 supports the concept of smart manufacturing, in which interconnected systems and gadgets interact and collaborate autonomously to optimize production processes. Predictive maintenance is important in smart manufacturing because it ensures vital equipment's durability and availability while minimizing production disruptions.

While 5G is currently accessible, the number of manufacturing applications it will power is mostly uncertain. According to a recent Accenture study, 5G-enabled factories may increase overall productivity by 20-30%, including 50% faster assembly time, 20% longer asset life, and 90% better defect detection. 2023 is the year to build a 5G network backbone that supports the following decade's manufacturing and corporate expansion. The smart factory has IoT sensors implanted in its production equipment that collect real-time data on characteristics like temperature, vibration, and energy use. This information is effortlessly incorporated into a centralized data platform, which is gathered, processed, and analyzed with advanced analytics algorithms. 

According to a PwC report, 72% of manufacturing organizations have already incorporated Industry 4.0 technology, ranking predictive maintenance as one of the most popular applications. The study also found that organizations participating in Industry 4.0 efforts realize considerable operational efficiency, quality, and cost savings increases.

Regional Insights

North America: Dominant region with 31.3% market share

North America is the most significant global market shareholder and is estimated to grow at a CAGR of 31.3% over the forecast period. North America will dominate the worldwide predictive maintenance market during the forecast period, owing to the increasing usage of predictive maintenance solutions based on advanced technologies such as IoT, cloud computing, machine learning, and artificial intelligence (AI). 

Additionally, regional organizations implement predictive maintenance solutions to detect operational performance issues while improving maintenance practices and reliability. The US has the most significant market share in North America's predictive maintenance market. The country's prominence in the region stems from several well-established firms contributing to market income. These players are using new methodologies and making significant investments to provide sophisticated solutions. Furthermore, some important players, such as Microsoft, AWS, IBM, and others, are helping to drive market growth in the United States.

Europe: Fastest growing region with the highest CAGR

Europe is anticipated to exhibit a CAGR of 31.0% over the forecast period. The need for predictive maintenance solutions is growing in Europe, owing to increased organizational investments and an understanding of the value of predictive maintenance technology in gaining a competitive edge.

• For example, many European military defense firms employ predictive maintenance to ensure high spare component availability, which is critical for fleet maintenance. This aided in studying logistical obstacles, financial risk, and economic situations, resulting in a more efficient supply chain and less expensive aircraft repairs. 

Asia-Pacific is expected to be the fastest-growing area in the worldwide market in terms of CAGR because of tremendous potential in undeveloped markets such as India and Singapore, where numerous sectors are quickly expanding. In the Asia Pacific region, predictive maintenance solution vendors are creating AI and IoT-enabled predictive maintenance systems to improve predictive maintenance services throughout the region.

Furthermore, significant growth in IoT applications will likely expand the Chinese market. The increasing implementation of various modern technologies, including big data, IIoT, and AI, will contribute to market growth over the next ten years. There has been a growing use of onboard electronics and intelligent sensors that can communicate with cloud-based analytics systems in recent years. Device vendors are expected to examine the servicing requirements and the operating conditions of the corresponding equipment ahead of time, which helps ensure operational efficiency. 

The Middle East and Africa are expected to experience consistent growth in the industry. The growing demand for more cost-effective predictive maintenance solutions and a desire to reduce machine breakdowns will drive expansion in the predictive maintenance market throughout the region.

Predictive Maintenance Market Segmentation Analysis

By Components

The solution category held the most significant market share in 2023. It will likely continue to do so during the forecast period, owing to rising demand for IoT-based predictive maintenance solutions and increased industry awareness of the need to deploy cost-effective solutions. These solutions commonly incorporate data collecting, analytics, predictive modeling, visualization, and integration with existing enterprise systems. Organizations can use predictive maintenance technologies to monitor equipment health, discover anomalies, predict probable breakdowns, and plan maintenance actions. 

The solution segment is further divided into integrated and standalone solutions. Among these, the integrated solutions segment is expected to lead the market during the forecast period due to the growing need for customized solutions and application-specific solutions across various industry verticals.

Similarly, predictive maintenance services include a wide range of consulting, implementation, integration, training, and support services offered by technology vendors, system integrators, and consulting firms to help organizations adopt and maximize the value of predictive maintenance solutions. These services could comprise an initial assessment and readiness evaluation, solution design and customization, data integration and configuration, model building and tuning, user training, and continuing technical support and maintenance. 

The services section is divided into three categories: deployment and installation, support and maintenance, and consultancy. Among these, the deployment and installation services segment is expected to dominate the market in the coming years, owing to rising demand for predictive maintenance services in industries such as automotive and transportation, energy and utilities, and aerospace and defense.

By Techniques

The vibration monitoring sector dominated the global predictive maintenance market due to its ability to detect and diagnose faults and give information about the machine's life span and potential failure mode. Vibration monitoring measures and evaluates mechanical vibrations in rotating machinery, equipment, and structures to determine their status and identify probable problems or failures. This method employs vibration sensors or accelerometers to gather data, which are then evaluated to detect abnormal vibration patterns such as excessive amplitude, frequency, or phase shifts. Vibration monitoring enables organizations to spot issues such as imbalance, misalignment, bearing wear, and structural faults early on, allowing for proactive maintenance and repair to avoid catastrophic failures, reduce downtime, and improve equipment reliability. 

The fluid analysis segment had the greatest CAGR during the forecast period due to its capacity to detect liquid contamination and reduce uncertainty, risk, and reactive work for a maintenance department. Fluid analysis, often known as oil analysis or lubricant analysis, is the process of testing and analyzing the characteristics and impurities in fluids such as oil, hydraulic fluid, coolant, or lubricants used in machinery and equipment.

Additionally, fluid sample analysis allows businesses to analyze the quality of equipment components, detect wear, corrosion, or contamination, and identify potential problems such as bearing failures, fluid leaks, or equipment malfunctions. Fluid analysis assists businesses in optimizing maintenance schedules, extending equipment lifespan, and reducing downtime by identifying and proactively addressing maintenance issues.

By Deployment

On-premise deployment had the most significant market share in 2023 and is likely to remain during the projection period, owing to growing data privacy concerns about cloud infrastructure. As a result, most firms choose to have their own servers and data centers to successfully run their internal and external software solutions, increasing demand for on-premises solutions. 

The cloud-based solutions segment is predicted to grow the quickest over the forecast period, owing to increased awareness of the benefits of cloud solutions, such as faster data processing, direct IT control, efficient resource usage, and cost-effectiveness. Furthermore, leading suppliers operating in the global market are providing cloud-based solutions for effective automation of equipment maintenance while maximizing related revenues.

By Organization Size

Large companies account for a sizable portion of the worldwide predictive maintenance market, owing to businesses' rising desire to optimize and automate their operational maintenance processes through predictive maintenance solutions. Large corporations frequently run complex manufacturing facilities, industrial plants, and infrastructure with a wide range of equipment and assets. Large companies can use predictive maintenance to improve maintenance strategies across their whole asset portfolio, prioritize maintenance tasks based on criticality and risk, and link predictive maintenance data with other enterprise systems like ERP and asset management.

Furthermore, downtime and assets are relatively inexpensive in large organizations. Thus, demand for predictive maintenance solutions rapidly expands in large organizations worldwide.

Small and medium-sized firms (SMEs) are expected to develop at the quickest CAGR during the estimated period, owing to increased expenditures in new establishments and an increase in small and medium-sized businesses worldwide. Cloud-based predictive maintenance solutions and managed services suited to SMEs' demands and financial constraints allow these businesses to implement predictive maintenance without significant upfront investments in infrastructure or knowledge. Predictive maintenance helps SMEs improve asset reliability, reduce maintenance costs, and increase competitiveness in their particular markets. 

By End-User

The manufacturing category dominated the global predictive maintenance market, owing to the increasing demand for equipment maintenance such as machinery, elevators, industrial robots, and pumps to reduce overall downtime. Furthermore, the rise of Industry 4.0 is projected to increase demand for predictive maintenance in the future years.

The energy and utilities market is expected to grow the fastest during the forecast period, owing to an increased requirement to monitor and repair assets and improve machine efficiency and dependability. Furthermore, the increased demand for predicting the failure of old components in energy and utility infrastructure is driving industry growth.

Recent Developments

• May 2024- Tech Mahindra and IBM helped enterprises accelerate the adoption of trustworthy generative AI using Watsonx.
• May 2024- SAP SE (NYSE: SAP) announced NEC Corporation (TSE: 6701 "NEC") has selected SAP S/4HANA Cloud via the RISE with SAP solution, which is hosted on Amazon Web Services (AWS).