Rockwell Automation Study Finds OEMs Slash Downtime Recovery 40%, Saving $3.6M
Rockwell Automation’s research of 500 OEM leaders shows top machine builders cut average downtime recovery by 40%, reducing 40-hour outages to under 24 hours and saving roughly $3.6 million per incident. It also finds leading OEMs embed expertise into equipment and deploy digital twins, AMRs and cybersecurity for consistency.
1. Research Overview
Rockwell Automation released a global study based on insights from 500 OEM leaders that examines how machine builders navigate workforce instability, supply chain volatility and cost pressures. The report highlights a shift from focusing solely on machine performance to emphasizing recovery speed, operational consistency and data-driven decision-making.
2. Rapid Recovery Findings
The study reveals average outages last 40 hours and cost $3.6 million, yet top OEMs now design systems to restore performance in under 24 hours. Faster recovery is identified as a key profitability lever, protecting customer revenue and reinforcing trust.
3. Workforce and Technology Strategies
With turnover rates reaching 47% in some regions, leading OEMs embed expertise into both machines and workflows to reduce reliance on individual workers and accelerate onboarding. They also apply digital twins, autonomous mobile robots and collaborative robots strategically to build quality into designs and ensure consistent deployment.
4. Cybersecurity as Differentiator
High-performing OEMs are integrating cybersecurity into product design from the outset, treating security with the same rigor as safety. This approach is helping to streamline market access, minimize delays and strengthen customer confidence in increasingly connected industrial environments.