Maintenance 2.0: Bridging the Industrial Skills Gap with IIoT and AI

Overview of the April 2 Webinar

Plant Engineering partnered with Advanced Technology Services (ATS) to host a webinar that examined recent survey findings from manufacturing executives and operations staff. The discussion focused on maintenance trends, emerging technologies, and the critical skills gap facing the industry today.

View the archived webinar. Download the full survey report.

Key Survey Findings

• 76% of facilities employ a preventive maintenance strategy.
• 60% still rely on a run‑to‑failure approach.
• 52% use a computerized maintenance management system (CMMS).
• Top causes of unscheduled downtime: aging equipment (34%), mechanical failure (20%), and operator error (11%).

These data underscore the need for reliable, data‑driven maintenance practices to unlock productivity and profitability.

Expert Q&A Highlights

Compensating for an Aging Workforce

Jim Freaner, Senior Director, ATS: The most effective strategies include hiring motivated, quick‑learning candidates; establishing mentorship programs that pair near‑retirees with newcomers; leveraging technology to capture institutional knowledge; and transitioning veteran technicians into instructor roles. Currently, 90% of our instructors are former ATS technicians and 100% are former skilled tradesmen.

Shifting from Reactive to Predictive Training

Jeff Kosiorek, VP, ATS: Predictive training reduces costly shutdowns—70‑80% of equipment stops are human‑error related. At ATS, we assess technicians within 90 days of hire using a validated, EEO‑compliant test covering 57 technical subjects. This assessment informs a personalized career path and supports our “Live Safety 24/7” culture.

Impact of Machine Learning on Maintenance

Jim Freaner: While AI and machine learning promise increased flexibility, adoption will evolve gradually due to security and workforce readiness challenges. In the meantime, robust CMMS data paired with advanced analytics can unlock predictive insights before full AI solutions mature.

Improving Skilled Labor Retention

Jeff Kosiorek: Compensation matters, but culture is the real lever. Our ATS culture is built on Live Safety, Value Employees, Engage Customers, and Drive Results. We focus on emotional intelligence, transparency, and respect—principles that foster loyalty and reduce turnover.

Maximizing a Legacy CMMS on a Tight Budget

Jim Freaner: Many plants underutilize existing CMMS capabilities. Integrate spare‑parts data, use CMMS for job‑kit planning, and refine job plans with detailed, illustrated standard work. These steps can enhance performance without new software investments.

Integrating Predictive Maintenance (PdM)

Jeff Kosiorek: PdM complements preventive schedules by spotting early warning signs—thermography, vibration, oil analysis, and ultrasonic detection. Implementing PdM reduces downtime, improves safety, and cuts overtime costs.

Key Data for Machinery Health

Jim Freaner: Remote sensing—temperature, vibration, current draw—provides real‑time insight into critical assets. Start with low‑cost, high‑impact sensors and scale as expertise grows.

Remote Support Infrastructure

Jeff Kosiorek: Our support model relies on three pillars: a maintenance forum connecting clients to ATS subject‑matter experts; a rapid‑response expert network; and a proprietary technician hub that offers real‑time access to equipment documentation. This framework accelerates problem resolution and reduces downtime.

Advanced Technology Services (ATS) is a global leader in reliability‑centered maintenance and MRO services. With 35+ years of experience, ATS delivers measurable productivity gains for Fortune 500 manufacturers through skilled workforces, standardized processes, and smart technologies. Contact us today to learn how we can help your plant thrive.