Top 5 predictive maintenance case studies from Plant Services in 2025
Plant Services case studies consistently rank among our most-read content because they show how maintenance and reliability strategies perform under real operating conditions. This Top Five list draws from standout case studies published over the past several years, highlighting approaches that have delivered measurable improvements in uptime, cost control, and asset performance. From AI-enabled predictive maintenance programs to enterprise-scale data integration and proactive service models, these examples reflect lessons that offer practical insight into how leading organizations have moved from reactive maintenance to more predictive and prescriptive strategies.
Top Plant Services case studies
1. AI-powered maintenance cuts downtime and costs for Fiberon’s manufacturing operations
Learn how one company avoided $274,000 in costs and 178 downtime hours over the course of an AI pilot while achieving a 2.5x return on investment.
2. IFS and Rolls-Royce connect the automated data pipeline
The partnership combines double the AI expertise to power prescriptive maintenance.
3. Advanced IoT and AI solidify KONE’s elevator and escalator predictive maintenance services
Learn how KONE achieved 70% more proactive fault detection and 40% fewer service disruptions across connected people-flow assets.
4. Case study roundup highlights proactive and predictive maintenance successes
These six maintenance and reliability case studies illustrate how emerging technologies and strategic condition monitoring are helping plants reduce downtime and enhance asset performance.
5. 6 case studies illuminate the value of predictive and prescriptive maintenance
Maintenance and reliability best practices are continually improving and so are the technologies that support them.
Other standout case studies from 2025
Inside Perdue Farms’ award-winning maintenance culture
As the sole winner of the 2025 Culture Improvement Awards, the company's Concord plant cut mechanical downtime by over 50%, showing measurable progress in maintenance and reliability.
Centralized data platforms slash maintenance hours at Cosmo Oil refineries
Real-time data, AI, and predictive maintenance deliver ample efficiencies to three refineries, where engineers previously spent 70-80% of their time collecting maintenance data.
Syngenta boosts industrial pump efficiency with ITT VIDAR variable-speed motor
New technology enables variable-speed control without a traditional variable frequency drive.
Large-job inspection reporting time for the service contractor fell from 8-12 hours to under five minutes.