Preparation Saves Profits: Avoid Unplanned Downtime

Benjamin Franklin once highlighted the ripple effect of small oversights: “A little neglect may breed mischief. For want of a nail, the shoe was lost; for want of a shoe, the horse was lost; and for want of a horse, the rider was lost.” This proverb reminds us that seemingly trivial gaps can snowball into costly failures. At Novotek UK & Ireland, service leader Sean Robinson explains how thoughtful foresight and targeted investment can preempt such pitfalls.

While the original tale ends in lost battle, today’s industries face a different defeat—unplanned downtime. A recent ServiceMax survey found that 369 of 450 companies (over 80 %) experienced unplanned outages in the past three years.

Unplanned downtime can erode profits in many ways. In continuous‑process sectors—ranging from butchery and water treatment to steelmaking—shutdowns mean lost product and additional costs that bleed into the bottom line. Even for less process‑sensitive goods, a single upstream disruption can halt a just‑in‑time supply chain, jeopardising customer delivery commitments.

Half of respondents feared that a high‑profile outage would erode customer trust, and one in ten believed such a failure could be irrecoverable, ending the business.

Preventing Poor Performance

Novotek echoes the British Army’s six‑P principle: Prior planning and preparation prevent poor performance. In practice, this means investing in integrated oversight software and, crucially, in ongoing technical support.

Digital twins are a powerful tool: they replicate physical processes in software, allowing teams to safely test failure scenarios, evaluate product or ingredient changes, and even redesign entire lines without costly physical trials.

However, like unmanaged machinery, poorly supported digital twins can generate new inefficiencies. Effective implementation requires expert guidance to translate simulation insights into reliable operational changes.

Make Maintenance a Sure Thing

Many technology‑driven firms struggle to align perceived value between active equipment, the supporting infrastructure, and lifetime technical support. Upgrading robotics may show immediate financial returns, but invisible support layers often go uninvested in—until an outage reveals their absence.

ServiceMax data shows that average annual losses from unplanned downtime exceed £500,000 per company. While some businesses can absorb this hit, many can’t afford to risk it.

The survey also revealed that 60 % of respondents believe digital twins can prevent unplanned failures, and over 50 % plan to invest in support infrastructure in the coming years.

In 2013, only 15 % of companies considered new software implementations “very successful,” according to Wood, Hewlin, and Lah in B4B. This statistic underscores the need for expert industrial IT deployment and continuous support.

Novotek recommends programs such as our Accelerated Plan for GE Digital software, which delivers rolling technical guidance and support. By joining, companies position themselves within that successful 15 %.

Neglect breeds mischief. As industries grow more complex and interdependent, seemingly minor oversights can explode into major problems. Prioritise preparation, embrace digital twins, and secure the support that keeps your operations running smoothly.

The author is Sean Robinson, Service Leader, Industrial Automation Expert, Novotek UK & Ireland.