Study: Two-Thirds of Firms still Early in Maintenance Digitalization 

• New survey “Industrial Maintenance in Transition” by Fraunhofer IML and osapiens highlights major hurdles for companies to transform Maintenance, Repair and Operations 
• Less than 2 in 5 companies use digital solutions that provide real return on investment 
• Maintenance Maturity Index helps companies benchmark their progress  

Europe’s maintenance sector is showing growing appetite for digital transformation, as two-thirds (63 percent) of firms are embarking on their digitalization journey. This is according to a new study by the Germany-based software developer osapiens in collaboration with the Fraunhofer Institute for Material Flow and Logistics IML (Fraunhofer IML). It found that nearly all companies (92 percent) across the continent are confident in the impact of digital maintenance tools, but are struggling to make progress in their digitalization to drive a return on investment. 

“Many companies believe they are already digitally advanced, but what we typically see are isolated systems rather than fully integrated ones,” said Dr.-Ing. Thomas Heller, Managing Director of the Fraunhofer Smart Maintenance Community and Head of Department Facilities and Service Management at Fraunhofer IML. “The next step is connecting these systems – creating visibility across data, processes, and people. That’s where the true value of digital maintenance begins.”  

The study “Industrial Maintenance in Transition” surveyed 407 maintenance leaders in mid-sized manufacturing companies across the UK and continental Europe, exploring the state of maintenance transformation and barriers to progress.  

Reality Check: Fragmented Digitalization  

Almost all surveyed companies (92 percent) recognize the value of predictive and connected operations for their maintenance. Yet, digitalization remains uneven. 

When it comes to planning, about a third (31 percent) of organizations rely on ERP systems, while a similar proportion (29 percent) still use spreadsheets. For execution, 59 percent of companies still depend on Excel or Google Sheets, 49 percent use ERP systems, and 41 percent still work with paper-based checklists. Adoption of CMMS tools (Computerized Maintenance Management System) for execution remains limited with just 6 percent using one. 

CMMS platforms are a highly anticipated maintenance technology which is said to restructure reactive firefighting into intelligent Predictive Maintenance. Less than a third (28 percent) of respondents describe their processes as fully planned and preventive, while another 37 percent describe them as fully planned and reactive. The majority combine elements of both and often struggle to maintain consistency.  

Technology poses a problem, and organizations are slow to switch to fully integrated CMMS due to integration, with existing systems being the main hurdle (43 percent) followed by cultural resistance (38 percent). Around a third suffer from limited IT resources and a shortage of digital skills. 

Maintenance Maturity Index Determines the Path Forward  

For the survey, Fraunhofer IML and osapiens developed a Maintenance Maturity Index. This five-stage model shows how organizations progress from manual, reactive practices to intelligent, predictive maintenance. It allows firms to benchmark themselves against their peers and provides a practical roadmap. 

The index analysis reveals three key findings: 35 percent of European companies have reached Stage 2, having digitized the basics. Another 25 percent have advanced to Stage 3 and are using structured systems, such as CMMS or ERP modules. Only 15 percent have achieved higher maintenance maturity: 10 percent have integrated maintenance into production planning (Stage 4), and 5 percent operate fully predictive systems. A quarter of organizations remain at the lowest, reactive stage. 

AI to Usher in the Next Era of Maintenance 

Technological progress in maintenance maturity goes hand in hand with the adoption of AI, in terms of both potential and wariness of adoption. Most organizations currently use AI tactically: 43 percent for workflow automation, 40 percent for knowledge management via chatbots, and 34 percent for anomaly detection. Mid-sized firms prioritize quick efficiency gains over fully predictive or integrated strategies. 

ROI gap: From Confidence to Proof 

While 92 percent of firms are convinced that digital tools can deliver measurable ROI, few can demonstrate it with hard data. Adoption of KPI dashboards – one of the clearest indicators of return – stands at just 40 percent. Other ROI-proving tools, such as integration with ERP and production systems (34.5 percent) or digital SOPs (34.3 percent), remain below the halfway mark.  

“Companies know that digital maintenance delivers value,” said Daniel Schwarz, Co-Founder of osapiens Asset Ops. “What they need to do now is to make that value visible. Those that succeed will turn maintenance into a true source of competitive advantage.”  

The full Maintenance in Transition Report can be downloaded here. 

About the Survey  

The report “Industrial Maintenance in Transition” by osapiens is based on a survey conducted in July 2025 among 407 senior maintenance leaders across Europe, including respondents from the UK, DACH, Benelux, and France. Participants represented mid-sized and large enterprises from industries such as manufacturing, automotive, consumer goods, and life sciences. Decision-makers surveyed included Heads of Maintenance, Plant Managers, and senior operational leaders responsible for planning, execution, and oversight of maintenance operations. The research was carried out by osapiens in collaboration with Fraunhofer IML, ensuring both methodological rigor and practical industry insight. The survey captures how organizations are positioned on the newly developed Maintenance Maturity Index and identifies the barriers, drivers, and opportunities shaping the future of digital maintenance in Europe.