Unmasking the Cost of Downtime: How Industrial DevOps Can Save Manufacturers Millions

Unmasking the Cost of Downtime: How Industrial DevOps Can Save Manufacturers Millions

In today’s manufacturing landscape, downtime significantly threatens both productivity and profitability. According to the latest State of Industrial DevOps Report, each hour of downtime costs U.S. manufacturers an astounding $4.2 million, with an average shutdown costing $126 million. With half of all downtime traced to coding and operational technology (OT) issues, these findings reveal the high cost of relying on outdated practices in industrial environments.

The Hidden Vulnerabilities in Industrial OT

The report, based on a survey of 200 U.S. executives, identifies several leading causes of downtime in OT environments:

• Cybersecurity breaches are responsible for 47% of downtime, highlighting the risks that have arisen with the increase in connected devices.
• Hardware malfunctions account for 45% of unplanned outages, followed closely by coding and software issues at 41%.
• Human error and environmental factors make up 32% and 25% of downtime causes, respectively.

Many of these failures could be minimized with systematic coding practices. However, the current approach to industrial code management remains inefficient. On average, organizations spend 10 times more time (45 hours per month) debugging code than reviewing it, leaving errors unaddressed. This figure rises to an astonishing 77 hours per month in sectors like retail and material handling, where downtime is particularly costly.

The Hidden Costs of Quick Fixes

The report reveals that 79% of respondents rely on ad hoc fixes to maintain continuity. While these quick solutions may restore production temporarily, they often leave systems vulnerable. Ad hoc fixes can bypass proper documentation and quality control, introducing security risks that can escalate into more serious failures.

Without a unified platform for code visibility and control, manufacturers struggle to apply security updates consistently across their operations. This lack of oversight increases the risk of malfunctions and hinders effective recovery, as undocumented changes make troubleshooting difficult.

Industrial DevOps: A Solution for Modern Manufacturing

Industrial DevOps, which adapts IT DevOps principles to OT, offers a way to address these challenges. By embedding practices like automation, validation, and continuous quality control into OT systems, manufacturers can reduce downtime, boost productivity, and enhance resilience.

“Downtime erodes the thin line between profitability and failure in manufacturing,” notes the report. Coding errors and cybersecurity vulnerabilities are key drivers of costly outages, and adopting Industrial DevOps practices enables organizations to take proactive measures, securing operations and maximizing productivity.

A Call for Change

Despite the benefits, 44% of respondents cite competing priorities as a barrier to Industrial DevOps adoption, with 39% indicating limited buy-in from management. However, the case for change is strong: organizations that integrate Industrial DevOps principles are better positioned to mitigate risks and improve operational efficiency.

To explore the complete findings of the State of Industrial DevOps Report and understand the potential financial impact on your organization, download the full report.

Related articles:

• Unplanned Downtime: Causes, Calculations, and Cures
• Are You Underestimating the Cost of Manufacturing Downtime?
• The Cost Of Downtime In Manufacturing