ABB and Sapio Research has released a new global report, based on a survey of 3,600 senior decision-makers across various sectors
ABB, in partnership with Sapio Research, has released a new global report, based on a survey of 3,600 senior decision-makers across various sectors, finding that 55% of respondents have a strategic and proactive plan to modernise facilities and eliminate obsolete components
Despite awareness rising, the data shows that 44% of leaders experience equipment-related interruptions at least monthly, with 14% reporting stoppages every single week, indicating significant financial and operational risks. The majority estimate that sudden disruptions cost between $10,000 and $500,000 per hour; for 7%, this figure is even higher.
The report found key gaps between planning and execution. 55% of industry partners claimed to have a proactive modernisation strategy, but only one in five of those facing weekly interruptions actually implement this plan. Of the 30% dealing with monthly issues, just 34% actively manage life-cycle processes for their facilities and assets.
Oswald Deuchar, global head of Modernisation Program, ABB Motion Services, said, “Unplanned downtime is costing industry up to half a million dollars per hour – yet one in three businesses hasn’t modernised their motor-driven systems in the last two years. That’s more than a missed opportunity; it’s a silent crisis. Our research shows that those who shift from reactive firefighting to forward-looking life-cycle strategies experience fewer failures and greater resilience. A key challenge, though, remains in justifying the up-front investment. With some applications, upgrading obsolete, inefficient equipment can generate return on investment in less than two years, but leadership buy-in is often hard-won.”
The communication gaps remain, despite the high hourly cost of unplanned downtime; over a third of respondents find it either somewhat or very difficult to articulate the return on investment (ROI) of modernisation projects to senior leaders. Meanwhile, 17% of businesses 'rarely or never' include the impact of lost productivity in their capital investment decisions.
Cost continues to be the top barrier to modernisation for 28% of industrial players, among the 66% who have undertaken an upgrading and retrofitting project in the past two years. Over a quarter explicitly did so to reduce stoppage risks, underscoring that the link between continuous life-cycle management and operational reliability is still not fully understood or acted on —even by many modernisation proponents.
Deuchar said, “We’re hoping this report opens some eyes. Modernisation isn’t just about replacing old parts; it’s about rethinking performance. With 44% of industrial players facing monthly setbacks, the case for smarter asset management has never been more urgent. ABB’s approach combines digital intelligence, modular retrofits, and circularity principles to turn yesterday’s equipment into tomorrow’s high performers. This is how we enable clients to trade last-minute fixes for long-term foresight. Because today, uptime is a mandate for a more competitive future.”
