Stop planning and start executing on digital maintenance

Key Takeaways

• 39% of facilities plan to implement artificial intelligence (AI) within the next year, up from 28% a year earlier
• Mobile applications for maintenance tracking posted a 16% year-over-year gain in perceived importance
• Resistance to smart factory initiatives is eroding, with a 13% decrease in respondents who are not implementing such initiatives
• Plants are shifting from training employees on predictive maintenance to partnering with technology vendors
• Prioritizing mobile and real-time visibility is crucial for staying competitive

Introduction to Digital Maintenance

The 2026 Plant Engineering State of Manufacturing Operations & Maintenance report highlights the increasing adoption of digital tools and smarter infrastructure in the manufacturing industry. With 39% of facilities planning to implement AI within the next year, it is clear that digital transformation is no longer a future-state ambition, but a present-day necessity.

The Shift Towards Digital Transformation

The report notes a significant increase in the perceived importance of mobile applications for maintenance tracking, with a 16% year-over-year gain. Additionally, resistance to smart factory initiatives is decreasing, with a 13% drop in respondents who are not implementing such initiatives. This shift towards digital transformation is driven by the need for improved reliability, efficiency, and resiliency.

Changing Response to the Skills Gap

The industry is changing its response to the skills gap, with an 11% drop in plans to train employees on predictive maintenance and an 11% increase in plans to partner with technology vendors. This is not a retreat from workforce development, but a recognition that internal teams cannot be expected to master every emerging technology while keeping production running.

Comparison of Digital Maintenance Strategies

Actionable Findings for Plant Leaders

Plant leaders should prioritize two key findings:

1. Mobile and real-time visibility: Invest in mobile applications, real-time performance monitoring, and AI-enabled tools to stay competitive.
2. Redefine supplier expectations: Expect greater collaboration in implementation, flexible and scalable solutions, and contract discussions that reflect this change.

Bottom Line

The manufacturing industry is undergoing a significant shift towards digital transformation, driven by the need for improved reliability, efficiency, and resiliency. With the increasing adoption of digital tools and smarter infrastructure, plants that fail to prioritize mobile and real-time visibility and redefine their supplier expectations risk falling behind. By acting on these findings, plant leaders can stay competitive and thrive in a rapidly changing industry. According to the report, 72% of respondents believe that digital transformation will have a significant impact on their operations within the next two years, making it essential for plants to start executing on digital maintenance strategies now.