A recently published study by Fluke Corporation reveals the true cost of downtime in industrial manufacturing.

The survey, conducted by Censuswide, interviewed 600 respondents representing food and beverage, oil and gas, life sciences and automotive manufacturing companies in Germany, the UK and the US. Last year, 61% of manufacturers suffered unplanned downtime, costing the industry up to $852 million per week.

Downtime Is Common

48% of companies report between six and ten outages per week, and almost one in five (19%) face between 11 and 20 weekly outages. 45% of businesses reported outages lasting up to 12 hours, and 15% experienced downtime of up to 72 hours.

Globally, the risks are highest for large companies. 40% of organisations with more than 50,000 employees report between 11 and 20 outages per week, and half of these organisations experience outages lasting up to 72 hours.

“Our research paints a compelling picture: manufacturers are caught in a cycle where downtime directly undermines competitiveness, and too many are forced to settle for piecemeal fixes,” said Parker Burke, Group President at Fluke Corporation.

Average Costs

According to the report, the average cost is $1.7 million per hour, meaning that a single outage can result in losses of up to $42.6 million.

While the number of outages is fairly consistent across the three regions studied, there are differences in costs.

In the UK and Germany, losses can reach up to $62.7 million, while the global average is much lower at $40.8 million per outage.

“The data shows that outages can no longer be seen as just an operational problem. It is a real risk to competitiveness and business value,” says Burke.

Increasing Resilience

The report found that many companies remain fragmented in their response. Manufacturers are spreading their digital investments across multiple tools – such as predictive maintenance (12%), digital twins (12%) and condition monitoring (13%) – rather than implementing integrated reliability strategies.

“Our research shows a stark reality: too many manufacturers are stuck reacting to outages instead of getting ahead of them. Quick fixes might keep things going for a while, but they don’t build long-term sustainability,” Burke said.

Text: Vaula Aunola   Photo SHUTTERSTOCK

Whether it is a factory, a railway, or a power plant, a single breakdown can grind operations to a halt, disrupt services, and trigger a chain of costly delays. Sometimes, all it takes is one missing spare part to bring an entire system to a standstill.

Tomáš Hladík believes it’s time to rethink the role of maintenance—and to remember that spare parts management, too, is a critical component of any effective maintenance strategy.

“Maintenance must move from the back office to the boardroom,” he insists. “It shapes competitiveness, resilience, and sustainability across European industry.”

Based in Prague, Czechia, Tomáš bridges industry, academia, and international collaboration. At the Czech University of Life Sciences Prague, he teaches courses on supply chain efficiency and modern maintenance strategies.

One of his key academic contributions lies in the field of Reliability and Risk Treatment–Centred Maintenance. In his research, he has applied methodologies such as Reliability-Centred Maintenance (RCM) and Risk-Based Inspection (RBI).

In his paper, Monetising Data in Maintenance, he explored how digitisation and Industry 4.0 technologies – such as IoT and IIoT – can optimise spare parts inventory. In this study, he proposes models for big data monetisation and outlines eight best practices for effective spare parts management, including inventory segmentation, criticality assessment, and forecasting.

Modernising Maintenance Education

As a Principal Consultant at Logio—a European consulting and technology firm specialising in supply chain management—Tomáš has spent nearly two decades translating theory into practice. He works closely with manufacturers and retailers to streamline their operations and achieve measurable reductions in waste through data-driven decision-making.

Beyond his consulting and research work, Tomáš has helped to steer the future of maintenance education across Europe. As Vice Chairman of the Training Committee at the European Federation of National Maintenance Societies (EFNMS), he is helping to modernise educational programs, harmonise knowledge frameworks, and elevate professional standards. In this role, his goal is to align training across the continent and prepare the next generation of professionals for a future defined by digital transformation and sustainability.

“I’ve always blended business with academia,” Tomáš says. “It’s not just about teaching—it’s about connecting students with real-world projects and bridging the gap between theory and practice.”

Tomáš Hladík’s path into European maintenance leadership wasn’t planned. After finishing his engineering studies at the Czech University of Life Sciences Prague, he was invited to teach and, through a mentor, got involved with EFNMS in 2006.
“I was the youngest member for a long time,” he says with a smile. “Not anymore, but the industry still needs more young people. That’s a big challenge.”

After chairing the committee for several years, he is now helping to shape how maintenance professionals are educated across Europe. He values the power of networks his work with EFNMS provides: “If I need an expert in any country, I know exactly who to contact.”

He also contributes to the EFNMS Body of Knowledge, a guide to key areas in maintenance and asset management. With his background in supply chains, Tomáš has helped reframe spare parts management as a strategic issue—not just a logistics issue.

Optimising these systems, he says, improves reliability, cuts waste, and strengthens resilience.

“Spare parts aren’t just about storage anymore—they’re vital to long-term performance.”

Spare Parts: A Strategic Discipline

If there is one topic that consistently captures Tomáš Hladík’s attention, it is spare parts management—often overlooked but vital. At first glance, it may seem like a simple logistics issue: keep enough stock to avoid shortages. But Hladík insists it is far more complex.

“Not having critical spare parts could put you out of business quite easily,” he warns. “This is especially true in industries like power generation or oil and gas, but it is just as relevant for manufacturers or operators of complex technologies and fleets like trains or trams.”

A tram, for example, may consist of 12,000 individual components, but only around 2,000 are practical to provide as spares. Identifying these LRUs (“line-replaceable units”) requires deep knowledge, foresight, and coordination across design, procurement, production, and operations. It is part of Product Lifecycle Management (PLM) – another strategic process that integrates data and activities across all stages of the life cycle of a complex machine, such as a train or tram.

“Some manufacturers still guess,” Hladík admits. “That creates enormous risk. Underestimate, and you face downtime and angry customers. Overestimate, and you tie up millions in unnecessary stock. Getting it right is a strategic advantage.”

From Selling Products to Selling Services

Looking ahead, Tomáš sees the rise of performance-based and full-service contracts—where providers guarantee uptime and performance over decades—as one of the most significant shifts in the industry.

“This is gaining more and more popularity in public transport—trams, trains, metros, aeroplanes,” he says. “Instead of buying a tram, for instance, the customer buys years of operation, hours of good performance measured by defined KPIs. The risk of downtime and inefficiency shifts from the operator to the manufacturer. That completely changes the business model.”

Large European manufacturers of trains or trams, he explains, are excellent at building trains. But selling long-term operations is another story. “They struggle because they don’t know what the actual reliability or MTBFs will be over 20 years. They’re guessing—and that makes pricing and managing these contracts very difficult.”

The shift toward full-service models in industrial assets is accelerating across Europe and around the globe. Western Europe is relatively advanced, Central Europe is catching up, and Eastern Europe is just starting to catch up. However, the direction is clear: customers are increasingly paying for outcomes rather than assets.

“You don’t need to own, for instance, the turbine anymore,” Tomáš says. “You rent it and pay only for the tonnes of steam it produces. The same model is being offered for automated logistics solutions, like automated warehouses or robotic handling in e-commerce fulfilment centres. The provider takes the risk for maintenance and inefficiency. This is already happening—and it will only grow.”

Challenges and Opportunities for Europe

Europe’s industrial sector is facing mounting pressure. Years of de-industrialisation have shifted core manufacturing to Asia, leaving the continent increasingly dependent on imports of electric vehicles, batteries, solar panels, and even advanced tech like robots.

“We’ve almost lost the ability to compete in the production of electric vehicles,” notes Tomáš. “Chinese EVs aren’t just cheaper—they’re often higher in quality than European models. The same story plays out in batteries and renewable technologies. These are technologies in which we once led, but now we repurchase them from Asia.”

Demographic shifts further complicate the picture. Countries such as Germany, Italy, Poland, and Finland are experiencing workforce shrinkage. Migration offers partial relief—Czechia, for instance, has welcomed 380,000 Ukrainian immigrants, half of whom are now employed and paying taxes, contributing positively to the economy—but it’s not a long-term fix, Tomáš says.

Despite the current challenges, Tomáš remains optimistic about Europe’s industrial future. He believes the continent must define its signature product for the 21st century—whether in pharmaceuticals, green technology, or sustainable infrastructure—and identify its next major growth market.

While Asia continues to dominate in many sectors, Tomáš views Africa’s rapidly growing population as a strategic opportunity.
“Europe is ageing and losing ground in automotive, AI, green technologies, and industrial automation. Meanwhile, China faces a population crisis and is turning to large-scale robotisation—using robots made in China. But as China’s domestic demand declines, it too is looking toward the market of the future: Africa. Whoever leads in Africa may well lead the next century,” Tomáš says.

To seize existing opportunities, Europe must also address a critical talent gap. Attracting young professionals to industrial and maintenance careers is essential for long-term EU industry competitiveness.

“Maintenance sits at the intersection of reliability, safety, and competitiveness,” Tomáš explains.

“It’s not routine work—it’s a dynamic, high-impact profession that shapes the future of industry. We need to communicate this clearly to the next generation.”

Education for a Changing Industry

Education is one of Tomáš Hladík’s enduring passions. As the industrial landscape undergoes rapid transformation, he insists that certain foundational principles must remain intact. “Skills like critical thinking, problem-solving, and the ability to learn form the foundation of every program,” he says. “They’re non-negotiable.”

Yet, the demands of modern industry require more than timeless skills. New competencies—such as predictive analytics, lifecycle management, digitalisation, and sustainability—are now central to effective maintenance. As technology evolves, so must the educational frameworks that support it.

“Technicians must learn how to maintain robots,” Hladík explains. “Not just gears and gearboxes, but sensors, grippers, and control systems. In 2023, Germany already had 430 industrial robots per 10,000 employees. In China, that number was 470, and the shift toward robotics has only just begun. This is the reality we must prepare for.”

Electric vehicles (EVs) present another emerging challenge. “In theory, EVs require less maintenance,” he notes. “But in practice, if your EV breaks down, you’ll wait a long time. There aren’t enough workshops with the skills to repair them. We urgently need more education and talent in this field.”

For Tomáš, the message is clear: education must evolve continuously. “Critical thinking, problem-solving, and the ability to learn will always remain at the core,” he emphasises. “But they must be combined with fundamentals and knowledge of emerging technologies and sustainability practices. That’s how we prepare the next generation.”

The Demographic Dilemma

Europe’s maintenance industry is navigating not only technological disruption but also a looming demographic crisis.

“By 2030, in the EU, most of the workforce will be between 50 and 65,” notes Tomáš. “That’s a serious challenge.”
While attracting young talent is essential, Hladík warns against sidelining older professionals.

“Many companies focus on hiring the young, but seniors hold a wealth of knowledge and experience. That expertise should be treated as a goldmine—not discarded.”

He points to Japan’s “super seniors” as a model: retired experts who continue contributing without rigid performance targets, mentoring younger colleagues and preserving institutional wisdom. In contrast, Europe often loses this expertise when workers retire and exit the workforce entirely.

Technology, Hladík believes, can help bridge the generational gap.

“With augmented reality, retired experts can guide younger technicians remotely offering real-time advice from home. It’s a new way of transferring knowledge without being physically present. We must explore these options.”

For Tomáš, maintenance is more than keeping machines running—it’s becoming a key driver of competitiveness and sustainability.

As European industry rapidly evolves, his vision highlights how innovation and experience together can transform maintenance into a cornerstone of industrial strategy.

“In our new reality, education must keep pace,” he stresses. “We can’t afford to fall behind.”

Text: Nina Garlo-Melkas
Photos: Mia Krizkova

Optimising Spare Parts: Hladík’s Eight Strategies for Data-Driven Maintenance

Tomáš Hladík presents a data-driven approach to improving spare parts management in his paper “Monetising Data in Maintenance: Data-driven Spare Parts Management,” published in the Maintworld magazine (issue 3/21).
Here are the key strategies he recommends:
1. Focus on Preventive Maintenance. Preventive (and predictive) strategies reduce the need to hold extensive inventories of spare parts.
2. Solve Process Inefficiencies: Identify and eliminate bottlenecks and data insufficiencies in spare parts workflows to optimise efficiency.
3. Segment the Spare Parts Portfolio. Classify parts by usage, value, and criticality, and work with each segment separately to optimise stock levels.
4. Evaluate Criticality and Assess which parts are essential for operations, prioritising their availability.
5. Utilise Accurate Forecasting Methods: Employ statistical models to predict demand accurately and prevent overstocking or shortages.
6. Handle Intermittent Demand Smartly. Use specialised techniques for parts with irregular usage patterns.
7. Consider Asset Lifecycle: Align spare parts decisions with the full lifecycle of equipment and machinery.
8. Clean and Rectify Master Data. Improve naming conventions and eliminate duplicates to enhance data quality and accuracy.

Since 2019, Roger Ham has led Kerry Group’s global maintenance transformation from his base in the Netherlands. With 148 manufacturing sites worldwide, the Irish-headquartered food ingredients company has spent the past six years standardising its maintenance operations, embracing digital tools, and redefining the role of maintenance across the organisation.
Roger Ham‘s mission as Kerry Group’s global maintenance lead has always been clear: to shift maintenance from a reactive cost centre to a strategic value driver.

“For decades, maintenance was often treated as a background function—essential, but rarely strategic. At Kerry, this view changed fundamentally in 2019,” he explains.

From Fragmentation to Standardisation

When Roger Ham joined the global function in 2019, each Kerry region operated almost independently of the others. Preventive maintenance (PM) programs were inconsistent, Hands-on Tool Time (HoTT) for technicians was low, and asset management was largely reactive.

“Kerry’s maintenance systems were fragmented. Each site had its own naming structures and approaches. A pump at one site could be labelled “P-100,” while another site might call it “Main Transfer 1.” Comparing performance data or sharing learnings was difficult,” Ham describes.

“148 sites meant 148 ways of doing things,” Ham recalls.

“If you’re not speaking the same language, you can’t analyse failures or improve effectively.”

To change the situation, a key focus at the beginning of Kerry Group’s transformations was master data standardisation: equipment hierarchies, naming conventions, maintenance task lists, and taxonomy.

“It was detailed, painstaking work—but essential.”

“If your master data is rubbish, everything else is rubbish too,” Ham says. “Planning, KPIs, digital tools—they all depend on clean data.”

This standardisation created a foundation for global benchmarking, improved planning and scheduling, and the introduction of new digital technologies.

Today, Kerry follows standardised processes across all its sites worldwide, embedding safety, quality, and operational efficiency into every maintenance task.

“Maintenance is finally at the table,” Ham says. “It’s recognised as adding value, not just spending money. We protect people, we ensure product quality, and we ensure the business runs efficiently. This all involves well-functioning maintenance operations”

Securing Tribal Knowledge

Kerry Group, like many manufacturing companies, is facing a retirement wave as veteran technicians with decades of experience are leaving the workforce, often taking critical knowledge with them.

“Some of these guys have personal notebooks full of unique know-how. When they retire, those notebooks disappear,” Ham explains.

To combat this loss, Kerry has systematically extracted and documented knowledge, creating standardised maintenance plans and digital libraries. Master data and uniform equipment naming conventions ensure that critical information resides in the system—not in someone’s pocket.

“Without proper master data, even the same equipment across different sites could be named differently, making it invisible in the system. Standardisation unlocks information and protects operational knowledge.”

Ham notes that the knowledge retention strategy has not only preserved decades of expertise but also enabled new hires and younger technicians to quickly access information, reducing reliance on retired staff and improving overall efficiency.

Planning and Scheduling: The Hidden Goldmine

One of Roger Ham’s main areas of focus is raising the recognition of maintenance planning and scheduling. He often begins his training sessions with a straightforward question:

“How much of a technician’s day is actually spent working with tools?”

Hands-on tool time is generally surprisingly only 30% of a technician’s day—the rest of the working time is lost to searching for parts, waiting for permits, or travelling between locations.

“If you raise hands-on tool time to 40% from 30%, you’ve effectively gained two extra technicians for every ten percent—no overtime, no new hires—just better organisation,” Ham says.

Planning and scheduling are often undervalued responsibilities. But when done correctly, they transform the hidden factory—the time technicians spend away from actual maintenance—into real productivity.”

At Kerry Group, planning and scheduling tasks have been redefined as a distinct operational function, separate from the responsibilities of site managers. While the same individual may perform planning and scheduling, the role itself is structurally independent to ensure focus, accountability, and strategic execution.

“Each site has its own maintenance planner and scheduler. This separation allows site managers to concentrate on broader operational leadership, while planners and schedulers drive maintenance efficiency.”

Now, at Kerry Group, well-functioning teams have achieved hands-on tool time levels of approximately 50%—a notable improvement that exceeds typical industry benchmarks.

The Lego Exercise to Build Competence

Kerry Group conducts two to three training programs annually for its planners and schedulers. These combine e-learning through Kerry’s academy with classroom sessions led by Roger Ham. Each training begins with the site manager present, ensuring leadership alignment.

Ham uses a Lego helicopter exercise during his training sessions to demonstrate the effects of poor planning. Participants receive kits with missing parts or confusing instructions, simulating real-world maintenance challenges.

“It perfectly mirrors a poorly planned job. The frustration is immediate, and people suddenly understand why planning matters.”

Training sessions include planners, schedulers, and site managers, emphasising accountability and operational understanding. By physically experiencing the inefficiencies of poor planning, teams internalise the value of standardised workflows.

From Paper to Mobile

Kerry has moved from paper-based work orders to mobile-enabled CMMS add-ons, providing technicians with digital tools to execute tasks efficiently. For years, Kerry used a CMMS for maintenance planning but relied on printed work orders on the shop floor. Technicians often filled in paperwork at the end of the week, resulting in inaccurate data.

“Let’s be honest,” Ham says. “Technicians would write down hours at the end of the week just to keep the system happy. The data wasn’t reliable.”

In 2024, Kerry launched mobile work order pilots in Northern Ireland and Scotland, integrating their CMMS with a mobile platform. Technicians now receive, execute, and complete work on smartphones. They can scan parts, log torque values, attach photos, and close work in real time.

The results: Improved data quality, faster feedback loops, higher engagement and the elimination of paperwork.

“Once people tried it, nobody wanted to go back to paper,” Ham says.

The platform uses AI in the background. When a maintenance request is logged, the system automatically searches for similar jobs, attaches standard steps, spare parts, and time estimates. This speeds up planning and improves consistency.

“A global rollout for the system is planned over the next two to three years.”

The system enhances data accuracy, minimises errors, and enables management to conduct cost and efficiency analyses.

Preventive maintenance planning benefits directly from these insights, helping Kerry avoid costly downtime and customer complaints.

“Technicians don’t want to work on paper anymore—they want mobile solutions. It makes their lives easier and attracts younger people to the profession,” Ham notes.

AI as a Strategic Tool

When discussing new technologies further, Roger Ham says he views artificial intelligence as an enabler, not a threat.

“AI is a helping device,” he says. “It can build preventive maintenance plans, analyse breakdown histories, suggest improvements, and support planners. In five years, it’ll be fully integrated.”

AI also plays a role in attracting younger talent. “The next generation doesn’t want to work with clipboards,” Ham notes. “They live on their phones. If we want them in maintenance, we need to provide modern digital tools.”

Accountability at the Top

One of Kerry’s most significant cultural shifts has been its adoption of an accountability model. While maintenance teams are responsible for execution, the site manager is ultimately accountable.

“If something goes wrong, it’s the site manager who goes to court,” Ham explains. “You can delegate responsibilities, but you can’t delegate accountability.”

This approach ensures that maintenance is not sidelined when production is under pressure. Preventive maintenance decisions are made at the top, aligning operational priorities with legal and safety obligations.

“Once the site managers understand their accountability and the workforce sees the benefits of planning, scheduling, and digital tools, everyone wins—safety, quality, efficiency, and engagement,” Ham concludes.

Key Takeaways – Kerry Group’s Maintenance Transformation

1. Standardise the Foundation

Consistent master data across all sites is essential. Without a shared structure, planning, KPIs, and digital tools cannot function effectively.

2. Separate *Planning/Scheduling and Supervision

Dedicated planners/schedulers prepare work at least one week in advance; supervisors coordinate execution. This structured approach raises technician tool time from around 30% to 50%.

3. Capture Tribal Knowledge

Veteran technicians’ expertise is systematically documented in standard task lists and libraries, preserving critical know-how for future generations.

4. Digitalise the Workflow

Shifting from paper to mobile work orders within CMMS has improved real-time data accuracy, accelerated feedback loops, and boosted technician engagement.

5. Use AI as an Enabler

AI assists with generating preventive plans, analysing breakdowns, and standardising job steps—supporting planners rather than replacing them.

6. Leadership Accountability Matters

Site managers bear ultimate accountability for maintenance, ensuring that operational decisions align with legal, safety, and reliability obligations.

7. Invest in People

Targeted training for planners, schedulers, and site leaders builds competence, ownership, and a shared understanding of maintenance
as a strategic function.

“Start with a dedicated planner-scheduler and clean up your master data,” Roger Ham says. “Those two steps change everything. After that, digitalisation and AI multiply the impact.”

Positive Outcomes from Kerry Group’s Shift

The changes implemented since 2019 have produced significant and measurable results:

• Hands-on tool time: Increased from 30% to ~50%, improving productivity without increasing headcount.

• Knowledge retention: Critical expertise preserved through digital libraries and standardised procedures.

• Operational efficiency: AI and mobile tools streamline workflows, reducing wasted time.

• Workforce engagement: Modern tools attract younger technicians, improving morale and retention.

• Strategic value: Maintenance now contributes directly to safety, quality, and operational performance.

Lessons for Industry Leaders

1. Maintenance as Strategy: Elevate maintenance from a cost centre to a strategic function.

2. Capture Critical Knowledge: Preserve expertise before experienced staff retire.

3. Optimise Hands-On Tool Time: Focused planning and scheduling unlock hidden productivity.

4. Leverage Technology: Mobile devices and AI enhance efficiency and attract younger talent.

5. Ensure Accountability & Training: Clear responsibilities and hands-on exercises reinforce compliance and operational understanding

Today, refineries, chemical plants, energy facilities, container terminals and infrastructure assets are using drones to access high, hazardous, or hard-to-reach areas that once required scaffolding, rope access, or even full shutdowns. These inspections can now be completed in a fraction of the time—cutting downtime, reducing risk, and saving money.

In a recent webinar hosted by the Belgium Maintenance Association (BEMAS), one case study showed how a 50-meter concrete silo was fully inspected in just one hour, with the results analysed digitally back at the office.  Similar efficiencies were seen in flare stack, tank, and cold box inspections, where drones captured visual and thermal data at scale to highlight insulation anomalies and other surface-manifested issues. This expanded coverage made it more likely to detect problems that traditional spot checks might otherwise miss. These insights then help inspectors and asset owners prioritise repairs and plan targeted, quantifiable NDT — potentially robotised — where it adds the most value.

Despite the advantages of modern technology, most inspections are still done manually, with personnel physically walking sites and taking measurements in often hard-to-reach or hazardous areas, said Jean-Louis Weemaes, Chief Business Officer at SkyeBase. He spoke alongside Martijn Cuyx, Innovation Manager at Vinçotte, and Grégory Gourdin, Head of Sales – Energy & Process Industries at Vinçotte, during the Smart Asset Inspection: Leveraging Robotics, Drones and AI webinar.

The webinar—still available for replay—spotlights how advanced technologies like drones, robotics, and remotely operated vehicles (ROVs) are transforming industrial inspections. Speakers from SkyeBase and Vinçotte emphasised a clear industry-wide shift: inspections are moving away from slow, manual routines toward remote, fast, data-driven operations powered by automation and AI.

Making inspections consistent and repeatable

One of the most promising advances in inspection technology is the integration of emission sensors directly onto drones. These sensors can detect over 20 types of gases at extremely low levels, giving quick, site-wide overviews of the emissions. Heat maps then show problem areas—red for high emissions, green for safe levels—so inspectors know precisely where to focus.

Such gas detection drones are widely used in industrial and environmental monitoring. They can detect gases, including methane, CO₂, and volatile organic compounds (VOCs), using sensors like Optical Gas Imaging (OGI) and Tuneable Diode Laser Absorption Spectroscopy (TDLAS). Companies like Finnish firm Aeromon, with its modular BH-series sensor units and cloud-based analytics platform, offer multi-gas detection solutions that can be mounted on drones or used handheld. Advanced systems like the Drone Flux Measurement (DFM) method by the Danish company Explicit integrate wind sensors to trace emissions back to their sources, even in complex environments such as coastal plants.

Such drones are increasingly deployed at oil and gas terminals, chemical plants, and for environmental surveys, enabling fast, non-intrusive inspections.

Drones are also improving consistency in routine inspections. By flying along pre-programmed routes, they can capture identical image sets year after year, making it easier to spot gradual changes like corrosion, cracking, or insulation wear. This repeatability supports more accurate trend analysis and helps engineers plan maintenance before problems escalate. As a result, predictive maintenance becomes faster, safer, and far more precise.

Remote and Connected Operations

Thanks to better connectivity, remote inspections are now more practical and efficient than ever, experts say.
“For routine inspections, an inspector doesn’t have to be on site anymore,” Weemaes described in the webinar. “They can log in, follow the live stream, and guide the drone operator from the office.”

Using Wi-Fi, 4G, or 5G links, inspectors can supervise field operations in real time, cutting travel requirements and site exposure.

For hidden or subsurface degradation (e.g., CUI, internal wall loss, bearings), drones provide condition-based indicators that identify areas for closer examination, enabling targeted, quantifiable (robotised) NDT. Those NDT tasks are performed by qualified personnel on site, while faster connections enable near instant transmission of results to experts off-site. All inspection data can be stored and organised on digital platforms. One of them is I-Spect – an AI-powered asset inspection platform that enables filtering, comparison, and sharing of asset trees, images, and annotations.

The main benefit is that asset owners have a single source of data: all inspection information, images, measurements and annotations in one place, processed and visualised with AI, often in 3D. No more scattered PDFs or separate reports; everything runs through one digital workflow.

Alongside the I-Spect platform from Belgium, several other tools are transforming how companies inspect and maintain their assets. DroneDeploy, based in the United States, offers a popular cloud-based platform for aerial mapping and inspections, especially in construction and energy. Percepto, based in israel, uses autonomous drones and AI analytics for continuous site monitoring, while Flyability, headquartered in Switzerland, builds Elios drones for confined spaces, featuring collision-tolerant designs to inspect hard-to-reach areas safely. In Finland, the company Kelluu provides innovative airship-based services for a wide range of inspection and monitoring tasks, offering longer flight times and lower emissions compared to traditional drones.

Each of these platforms offers its own advantages; some focus on real-time data visualisation, others on autonomous drone operations, and others on seamless integration with asset management tools. Together, they reflect a growing shift across industries toward more innovative, more digital inspection methods that are faster, safer, and powered by AI.

While manual inspections are still widely used, modern tools like drones are quickly gaining ground, experts emphasised during the BEMAS webinar. Many companies have already adopted drone technology, while others are actively testing or preparing for deployment. The shift from pilot projects to full-scale integration is accelerating—driven by clear improvements in safety, cost efficiency, and inspection quality.

Tools that centralise inspection data are making information more traceable and trendable. AI now automatically flags potential defects such as corrosion or cracks, with human inspectors performing final quality assurance. Some systems even support live streaming, allowing inspectors to guide drone operators remotely in real time—watching the feed and directing flight paths from an office or home.

Moving from reactive to proactive maintenance

Traditional inspections often require confined-space entry, scaffolding, and lengthy permitting. By contrast, drones and robotic tools have reduced the number of workers exposed to hazardous environments by up to 90%, while also cutting inspection costs by eliminating the need for scaffolding and insulation removal—expenses that can account for 50–70% of inspection budgets.

In the end, drones are helping asset owners shift from reactive fixes to proactive, data-driven maintenance. With autonomous flight, advanced sensors, and AI analysis, drones have evolved from simple inspection tools into key players in improving industrial reliability, safety, and sustainability.

“Early detection keeps assets in the inspect and maintain zone, where defects are still small and inexpensive to correct. As degradation progresses, costs rise quickly and the risk of failure increases,” explained Martijn Cuyx, Innovation Manager at Vinçotte, during the webinar.

By catching issues early, companies can extend the life of critical assets, minimise downtime, and prevent costly unplanned shutdowns. In this new era of inspection, maintenance isn’t just faster—it’s smarter, safer, and driven by data. The future of asset management is no longer reactive; it’s predictive, precise, and profoundly more resilient.

How Drones Are Changing the Way We Inspect, Monitor, and Respond

Drones are rapidly becoming essential across industries—from infrastructure and energy to emergency response and even wildfire monitoring. Their ability to access hard-to-reach areas, capture high-resolution data, and operate in hazardous conditions makes them ideal for tasks like:

Defence and boarder security. In defence, drones are becoming vital for surveillance, threat detection, and rapid response. Military-grade UAVs (Unmanned Aerial Vehicles) now patrol borders, monitor conflict zones, and support tactical operations with real-time intelligence. Initiatives like Europe’s “drone wall” show how autonomous flight and AI tracking are being scaled to protect critical infrastructure and national security.

Industrial, energy, and infrastructure inspections. Inspecting bridges, pipelines, tanks, railways, and power lines without shutting down operations; Surveying construction sites and managing progress remotely; Globally, drones are streamlining asset inspections. Equipped with high-resolution, thermal and lidar cameras, they detect corrosion, cracks, and leaks with sub-millimetre precision. Automated flight paths ensure consistent data collection, while AI enables predictive maintenance and defect tracking—reducing downtime and eliminating the need for scaffolding. Inspecting bridges, pipelines, and power lines without shutting down operations

Wildfire detection and rescue missions. Supporting search-and-rescue missions and disaster response; Tracking wildfires and mapping affected zones in real time; As wildfires become more frequent and intense due to climate change, drones are changing how we fight them. In the future, coordinated drone swarms could even autonomously drop water or create firebreaks. Future swarms of drones may even deploy water or firebreaks autonomously.

Environmental and emission monitoring. Monitoring crop health and irrigation in agriculture; Drones equipped with gas sensors can detect over 20 compounds at parts-per-million levels, generating heat maps that pinpoint leaks—even in windy conditions. This technology is now used in refineries, tank terminals, and offshore platforms to enhance safety and compliance.
Toward autonomy. Research and development are pushing drone technology toward full autonomy. Companies and agencies are testing drone fleets that can fly autonomously, share data across networks, and safely navigate complex environments. These systems are designed for large-scale tasks such as infrastructure inspection, environmental monitoring, and emergency response.

Nordic Drone Research Tackles Wildfires

As wildfires grow more frequent and intense due to climate change, Finnish researchers are turning to drones for early detection and smarter response. At the forefront is Eija Honkavaara, Research Professor at the National Land Survey of Finland, whose work in the FireMan project is reshaping wildfire monitoring.

“We have developed methods for detecting fires at an early stage and monitoring their progress,” Honkavaara explains.

Her team demonstrated real-time fire detection using drones equipped with compact cameras and onboard computers. These systems can identify ignition points quickly and transmit situational data to firefighting teams—crucial for targeting resources where they’re needed most.

“The biggest advantage of drones is that they enable digital and scalable solutions for rapid fire detection and situational awareness,” she says.
The project also explored digital twin technology—computer models of real environments that help predict fire behaviour and plan containment strategies. Honkavaara believes this approach will become standard in future wildfire response.

“When a fire is detected early, it doesn’t have time to grow out of control,” she notes.

Looking ahead, her research envisions autonomous drone swarms capable of operating in remote areas, communicating across networks, and even transporting water. While challenges remain—such as airspace management and connectivity—Honkavaara is optimistic.

“We are still in the research phase, but through demonstrations and cooperation with companies and practioners, applications can be put into practice and more autonomous drone systems will be part of firefighting in the coming years.”

With wildfires burning over half a million hectares annually in Europe alone, Honkavaara emphasises urgency: “Effective, technology-based methods should be adopted as quickly as possible.”

Drone Wall: Europe’s Digital Defense Against Aerial Threats

The EU is building a “drone wall” — a digital defence system of sensors, AI, and drones designed to detect and neutralise unauthorised aircraft before they reach European airspace.

Announced on October 16 as part of the Defence Readiness Roadmap 2030, the initiative was launched in response to a growing number of airspace violations and hybrid threats along the EU’s eastern borders.

Unlike a physical wall, the system will use radar, optical sensors, signal jammers, and AI tracking tools to create a virtual shield stretching from Finland to the Black Sea. It’s aimed at protecting EU and NATO borders from espionage, sabotage, and other emerging threats.

The project gained urgency following a rise in drone incursions and airport disruptions in countries such as Poland and Romania.

The Baltic states are leading the development, with Croatia, Latvia, and the Netherlands contributing technology and production.

Set to be operational by 2027, the drone wall marks a turning point in Europe’s defence strategy—signalling how drones have evolved from industrial tools to core components of even national security.

How Drones Are Changing the Way We Inspect, Monitor, and Respond

Drones are rapidly becoming essential across industries—from infrastructure and energy to emergency response and even wildfire monitoring. Their ability to access hard-to-reach areas, capture high-resolution data, and operate in hazardous conditions makes them ideal for tasks like:

Defence and boarder security. In defence, drones are becoming vital for surveillance, threat detection, and rapid response. Military-grade UAVs (Unmanned Aerial Vehicles) now patrol borders, monitor conflict zones, and support tactical operations with real-time intelligence. Initiatives like Europe’s “drone wall” show how autonomous flight and AI tracking are being scaled to protect critical infrastructure and national security.

Industrial, energy, and infrastructure inspections. Inspecting bridges, pipelines, tanks, railways, and power lines without shutting down operations; Surveying construction sites and managing progress remotely; Globally, drones are streamlining asset inspections. Equipped with high-resolution, thermal and lidar cameras, they detect corrosion, cracks, and leaks with sub-millimetre precision. Automated flight paths ensure consistent data collection, while AI enables predictive maintenance and defect tracking—reducing downtime and eliminating the need for scaffolding. Inspecting bridges, pipelines, and power lines without shutting down operations

Wildfire detection and rescue missions. Supporting search-and-rescue missions and disaster response; Tracking wildfires and mapping affected zones in real time; As wildfires become more frequent and intense due to climate change, drones are changing how we fight them. In the future, coordinated drone swarms could even autonomously drop water or create firebreaks. Future swarms of drones may even deploy water or firebreaks autonomously.

Environmental and emission monitoring. Monitoring crop health and irrigation in agriculture; Drones equipped with gas sensors can detect over 20 compounds at parts-per-million levels, generating heat maps that pinpoint leaks—even in windy conditions. This technology is now used in refineries, tank terminals, and offshore platforms to enhance safety and compliance.

Toward autonomy. Research and development are pushing drone technology toward full autonomy. Companies and agencies are testing drone fleets that can fly autonomously, share data across networks, and safely navigate complex environments. These systems are designed for large-scale tasks such as infrastructure inspection, environmental monitoring, and emergency response.

Text: NINA GARLO-MELKAS

Photos NLS Finland, shutterstock

One of the regulation’s most impactful measures—the digital battery passport—is set to launch in 2027. This tool will provide comprehensive visibility into each battery’s life cycle, enhancing transparency, supporting environmental sustainability, and improving operational efficiency throughout the value chain.

What Is the Digital Battery Passport?

The digital battery passport is an electronic document designed to compile and present essential information about a battery’s life cycle. It includes data ranging from the manufacturer and raw materials to the battery’s carbon footprint, recyclability, and maintenance history.

Each light mobility device (LMT) battery, every industrial battery with a capacity exceeding 2 kWh, and each electric vehicle battery will be assigned a unique identifier, accessible via a QR code affixed directly to the battery.

When a battery reaches the end of its service life and is recycled, its digital passport is closed. This ensures that the battery’s journey is documented from start to finish, enabling better oversight, safer handling, and more efficient material reuse.

“The battery passport makes the entire battery life cycle visible. It is a tool for transparency and responsibility, but also a tool for knowledge management,” explains Saara Haapamäki, Manager – ESG Advisory, KPMG.

EU’s Goal: A Responsible and Traceable Battery Chain

The primary purpose of the battery passport is to ensure that batteries meet the EU’s stringent environmental and safety requirements throughout their life cycle. It also establishes a harmonised reporting framework across all member states, enabling consistent data collection and regulatory compliance.

The passport’s data is divided into two categories: Public information, including the manufacturer, battery category, battery capacity, material composition, and sustainability information (e.g., carbon footprint and responsible sourcing).

Restricted information, such as battery condition, usage cycles, battery history, disposal instructions, and safety data. This information is accessible only to authorised entities, such as regulators and certified service providers.

“This is not just a technical system, but a change in the entire industry’s operating model. The regulation challenges companies to look at where materials come from and how information flows through the value chain,” Haapamäki emphasises.

New Obligations for Industry Players

Implementing the battery passport will require significant changes to how companies manage reporting and data systems. Manufacturers, importers, and distributors will be responsible for ensuring that every battery they place on the market has an up-to-date, properly maintained digital passport. This obligation introduces new requirements for digital infrastructure, data integration, and supply chain collaboration.

“For many companies, this means investing in new systems and processes. At the same time, it offers an opportunity to improve data management, supply chain predictability, and the ability to demonstrate responsibility,” Haapamäki notes.

The battery passport also makes it more difficult to procure raw materials anonymously from open markets. Every material and component must be traceable back to its origin, which enhances transparency but also increases administrative workload.

“A clear understanding of the stages in the battery supply chain helps to find solutions for reducing emissions and the carbon footprint,” Haapamäki adds.

Enabling Circularity and New Business Models

The battery passport plays a key role in facilitating recycling and reuse processes. It also empowers consumers by increasing awareness of the environmental impact of batteries, enabling more informed and responsible purchasing decisions.

By improving the traceability of materials, the passport supports the availability of critical raw materials and helps reduce cost pressures. It encourages the development of new service models, maintenance solutions, aftermarket services, and value-chain optimisation strategies.

“Companies that can demonstrate responsibility and traceability can gain a competitive advantage and strengthen their position in partner networks,” says Haapamäki.

The passport can accelerate the adoption of circular economy principles by enabling:

• Battery reuse and refurbishment

• Lifecycle-based service offerings

• Rental and subscription models

• responsible consumer choices

Companies that strategically leverage battery passport data can optimise material flows, reduce operational risks, and build trust with stakeholders. The passport transforms responsibility from a vague concept into a measurable and commercially viable asset.

Maintenance: Safety and Efficiency Through Data

In industrial settings, the battery passport introduces a new dimension to maintenance operations. When a technician scans the battery’s QR code, they gain access to real-time information about the battery’s structure, disassembly instructions, component composition, and safety guidelines.

“The battery passport is a practical aid for maintenance teams. It helps identify risks before maintenance work and enables monitoring of the battery’s condition throughout its life cycle,” Haapamäki explains.

This data streamlines maintenance planning, enhances safety, and supports predictive maintenance strategies. By tracking usage cycles and performance metrics, companies can schedule maintenance more accurately and extend equipment’s service life.

However, to fully benefit from the battery passport, companies must adapt their internal processes and IT systems not only to read it but also to update it with new data. This requires close collaboration between maintenance and IT departments but offers improved visibility and security throughout the production chain.

Environmental Impact and Sustainable Development

From an environmental perspective, the battery passport represents a significant step forward. It helps ensure that valuable raw materials—such as lithium, nickel, and cobalt—are recovered and reused rather than lost. By documenting the origin and composition of materials, recycling can be conducted more safely and efficiently.

“When the origin and composition of materials are known, recycling can be done more safely and efficiently. At the same time, the carbon footprint of the entire value chain can be monitored and reduced,” Haapamäki explains.

The passport also helps mitigate the risks associated with unethical mining practices and supports the EU’s broader goal of creating a more sustainable and self-sufficient battery materials sector. Transparency and data bring both environmental benefits and business advantages—two goals that have traditionally been seen as conflicting.

A Cultural Shift in Industry

Haapamäki states that by 2027 at the latest, the battery passport will be an essential part of everyday industrial operations.

“This is part of a larger change in which sustainability is no longer a separate area but an integral part of business. The battery passport makes it visible and measurable,” Haapamäki concludes.

As the industry adapts to this new framework, companies that embrace the battery passport early will be better positioned to meet regulatory requirements, build resilient supply chains, and lead the transition toward a more sustainable future.

Digital Battery Passport – At a Glance

What is it? An electronic document that tracks a battery’s life cycle—from production and use to recycling.
When is it coming? Mandatory in the EU starting February 18, 2027, under the EU Batteries Regulation (EUBR).
Applies to
• Electric vehicle batteries
• Industrial batteries, with a capacity greater than 2 kWh
• Light means of transport batteries
Why is it important?
✔ Increases transparency and
accountability
✔ Improves safety and maintenance efficiency
✔ Facilitates recycling and material traceability
✔ Supports sustainability and circular economy goals
How does it work? Each battery has a QR code that links to its digital passport. When the battery is decommissioned and recycled, the passport is closed.

Digital Battery Passport – At a Glance

Text: NINA GARLO-MELKAS Photo: Shutterstock