Cost Savings From Reduced Unplanned Downtime (Machine Health)

Evidence and data. Interviewees across industries consistently reported that Augury’s Machine Health solution significantly reduced unplanned downtime by enabling earlier detection of mechanical issues and more proactive maintenance. Key insights include:

• Across all organizations, interviewees emphasized that Augury’s continuous monitoring and diagnostic insights helped shift maintenance strategies from reactive to predictive, enabling better planning, fewer disruptions, and improved operational continuity.

• An interviewee at a global food and beverage manufacturer shared that over a three-year deployment across multiple sites, the solution helped avoid approximately 10,000 hours of unplanned downtime, resulting in the recovery of over 25 million pounds of product that would have otherwise been lost.

• One interviewee reported that within 12 to 18 months of implementation, one of their sites avoided over 220 hours of downtime, equating to more than $1 million in cost avoidance. This interviewee noted, “Augury has really helped with uptime, with catching machine failure well before it becomes an issue.”

• A maintenance and service leader at a large industrial refinery and petrochemicals conglomerate emphasized that Augury’s predictive alerts allowed teams to intervene before failures occurred, reducing emergency interventions and improving equipment availability.

Modeling and assumptions. Based on the interviews, Forrester assumes the following about the composite organization:

• Using Augury’s Machine Health solution, each site avoids 95 hours of unplanned downtime.

• Based on the organization’s annual revenue, the organization experiences $30,000 of lost revenue for each hour of unplanned downtime.

• The operating margin is 12%.

• The organization has 50 assets for each site using Machine Health, with rollout starting at five sites in Year 1, expanding to 15 sites in Year 2 and 50 sites in Year 3.

Risks. The reduction in unplanned downtime may vary depending on the following:

• The total hours of unplanned downtime may differ depending on the industry as well as the maturity of operations.

Results. To account for these risks, Forrester adjusted this benefit downward by 10%, yielding a three-year, risk-adjusted total PV (discounted at 10%) of $16.8 million.

Reduced Maintenance Spend (Machine Health)

Evidence and data. Interviewees reported that Augury’s Machine Health solution enabled their organizations to reduce maintenance costs by shifting from reactive to predictive maintenance strategies. Key insights include:

• Interviewees highlighted that Augury’s continuous monitoring allowed teams to detect early signs of wear or failure, enabling timely interventions that prevented more costly repairs and minimized labor hours.

• Interviewees shared that they experienced reductions in maintenance spend ranging from 5% to 30%, depending on asset type and deployment maturity. They attributed these savings to fewer breakdowns, more efficient scheduling, and a reduction in more expensive emergency repairs.

• An interviewee from a global food and beverage manufacturer emphasized that Augury’s insights helped maintenance teams focus their efforts on the most critical assets, reducing unnecessary inspections and extending the life of components.

Modeling and assumptions. Based on the interviews, Forrester assumes the following about the composite organization:

• The average annual maintenance cost per asset is $4,000.

• The composite organization reduces maintenance spend by 15% per asset due to earlier detection of issues, fewer emergency repairs, and more efficient maintenance scheduling.

• The composite organization uses Augury’s Machine Health solution to monitor 250 assets in Year 1, scaling to 750 in Year 2 and 2,500 in Year 3.

Risks. The reduction in maintenance spend may vary depending on the following:

• The baseline maintenance cost per asset may differ across industries and asset types.

• Organizations with already mature predictive maintenance programs may see smaller incremental improvements.

Results. To account for these risks, Forrester adjusted this benefit downward by 10%, yielding a three-year, risk-adjusted total PV (discounted at 10%) of $1.5 million.

Energy Savings (Process Health)

Evidence and data. Interviewees reported that Augury’s Process Health solution enabled more precise control of energy-intensive operations, particularly in environments where thermal processes are central to production. Natural gas is a key energy source in many industrial operations, particularly for heating and thermal processes. Key insights include:

• An interviewee from an industrial production company reported that prior to implementing Process Health, operators often ran equipment conservatively, over-drying materials or running at higher-than-necessary temperatures, to avoid quality issues. This led to excessive energy consumption. With Augury’s solution, the organization was able to optimize dryer performance and reduce gas usage without compromising output.

• The same interviewee estimated a 5% reduction in natural gas consumption, driven by improved control over drying temperatures and the ability to switch between production modes more efficiently, noting, “We’re no longer overheating equipment just to be safe; we know exactly how it’s performing.”

• Interviewees using Machine Health also noted qualitative benefits that  contributed to improvements in energy efficiency. One interviewee reported that the predictive insights from Augury enabled early detection of inefficient motor performance, reducing unnecessary energy use. Another interviewee highlighted that real-time visibility into equipment health allowed for better planning of maintenance activities, minimizing energy-intensive emergency interventions and ensuring continuous, optimized equipment performance.

Modeling and assumptions. Based on the interviews, Forrester assumes the following about the composite organization:

• The composite organization consumes 2.5 million MCF (thousand cubic feet) of natural gas annually across its operations.

• The average cost of natural gas in the US is $4 per MCF.

• With Augury’s Process Health solution, the organization reduces gas consumption by 5% annually through improved process control.

Risks. The energy savings may vary depending on the following:

• The proportion of energy-intensive processes within the organization’s operations.

• The baseline efficiency of existing process controls prior to implementing Augury.

• The geography of the organization and the associated natural gas (or other energy source) prices in that region.

Results. To account for these risks, Forrester adjusted this benefit downward by 30%, yielding a three-year, risk-adjusted total PV (discounted at 10%) of $870,398.

Profit From Increased Throughput (Process Health)

Evidence and data. Interviewees described how Augury’s Process Health solution enabled more consistent and optimized production, particularly in high-throughput environments where even small efficiency gains translate into significant financial impact. Key insights include:

• An interviewee from a manufacturing organization reported that Augury helped increase throughput by approximately 5% on production lines that were already operating at full capacity. The interviewee attributed this to improved process stability, reduced variability, and faster transitions between production modes. “We’re able to run more consistently and switch between products with less downtime,” the interviewee noted.

• The same interviewee emphasized that these gains were particularly valuable during periods of high demand when every additional unit produced translated directly into revenue.

• Interviewees from other industries noted that Augury’s predictive capabilities also helped reduce process interruptions and maintain optimal operating conditions, which indirectly supported higher output and better asset utilization.

Modeling and assumptions. Based on the interviews, Forrester assumes the following about the composite organization:

• The composite organization generates $20 billion in annual revenue, with 2.5% of that revenue tied to a single production line.

• The operating margin is 12%.

• The organization operates one line with Augury’s Process Health solution in Year 1, scaling to three in Year 2 and five in Year 3.

• Throughput on each line equipped with Augury’s Process Health solution increases by 5% annually, and 50% of this throughput increase is attributed to Augury.

Risks. The increase in throughput may vary depending on the following:

• The extent to which production lines are already optimized or constrained by other bottlenecks.

• The organization’s ability to act on Augury’s recommendations in real time.

• External factors such as supply chain limitations or labor availability that may limit the ability to capitalize on increased throughput.

Results. To account for these risks, Forrester adjusted this benefit downward by 30%, yielding a three-year, risk-adjusted total PV (discounted at 10%) of $7.5 million.

Unquantified Benefits

Interviewees mentioned the following additional benefits that their organizations experienced but were not able to quantify:

• Upskilled workforce and improved employee productivity. Interviewees across industries consistently reported that Augury’s Machine Health and Process Health solutions helped elevate the professionalism, confidence, and effectiveness of their maintenance teams. With access to timely alerts and diagnostics, technicians were able to prioritize their work more effectively, reduce time spent on manual inspections, and focus on the most critical issues. One interviewee described Augury “like a screwdriver” — a tool that technicians rely on daily to guide their actions.
  Interviewees also noted that Augury enabled better maintenance scheduling, allowing teams to shift from reactive to predictive workflows. Instead of responding to unexpected breakdowns, technicians could plan interventions in advance, reducing stress and improving operational efficiency. This shift contributed to a more structured and proactive work environment, where employees knew what to expect and could allocate their time more strategically.
  Several interviewees emphasized the time savings gained from being able to trust Augury’s alerts. Rather than spending time diagnosing issues manually or performing routine checks on healthy equipment, teams could act with confidence based on system insights. This not only improved productivity but also reduced unnecessary labor and overtime.

• Improved employee experience. The employee experience also improved, with interviewees noting a stronger sense of ownership, pride, and peace of mind. Knowing that they had a reliable system monitoring equipment health gave technicians greater confidence in their decisions and reduced the pressure of having to “catch everything” themselves. Additionally, interviewees observed the emergence of internal user communities across different sites, where technicians and reliability leaders shared learnings, best practices, and success stories related to Augury. One interviewee also highlighted that Augury helped preserve and transfer operational knowledge by digitizing machine health data and embedding predictive maintenance insights into daily workflows, which ensured that critical know-how is no longer dependent on individual experience. This shift enabled consistent decision-making regardless of who was on shift, enhancing long-term operational resilience and sustainability.

• Sustainability improvements. Interviewees reported that Augury’s solutions contributed to sustainability goals by reducing waste and emissions. By identifying inefficiencies early, teams could avoid overprocessing, reduce energy consumption, and minimize the production of defective goods. One interviewee emphasized that Augury helped their organization “run cooler and more consistently,” directly supporting environmental objectives. Another interviewee noted that early alerts helped prevent hydraulic fluid leaks, which could otherwise have significant environmental consequences.

• Improved safety of working environment. Interviewees reported that Augury reduced the need for manual inspections in hard-to-reach or hazardous areas, lowering the risk of injury. They also noted that by preventing unexpected equipment failures, the solution helped create a safer working environment for maintenance personnel and reduced the urgency of emergency interventions.

Flexibility

The value of flexibility is unique to each customer. There are multiple scenarios in which a customer might implement Machine Health and Process Health and later realize additional uses and business opportunities, including:

• Combining Machine Health and Process Health. One interviewee described the future potential of combining Machine Health and Process Health to create a more intelligent, adaptive, and cost-efficient production environment. While both solutions independently provide value, the interviewee emphasized that the true optimization opportunity lies in their integration.
  The interviewee envisioned combining Machine Health and Process Health to create a system that not only detects mechanical issues like a failing bearing but also understands the broader process context, for example, whether the system is running at the optimal point for balancing throughput, cost, and asset longevity. Today, organizations often lack visibility into how production decisions (e.g., running faster or slower, switching between lines) impact maintenance costs or component life. With integrated insights, teams could make data-driven trade-offs, such as accepting faster wear on a component during high-demand periods in exchange for increased output.
  The interviewee also noted that combining Machine Health and Process Health could help answer complex operational questions, such as whether to run one line at full speed or multiple lines at lower capacity when demand is low. These decisions can significantly affect profitability, especially in industries where margins are tight and operational flexibility is critical. Ultimately, the interviewee saw this convergence as a path toward a “smart operational system,” one that continuously learns, adapts, and guides teams toward optimal performance across cost, reliability, and throughput.

• Machine replacement decision support. One interviewee noted that Augury’s insights have the potential to inform long-term capital planning by identifying persistently underperforming assets or “bad actors.” By tracking how often a machine enters a failure state, even after repeated repairs, teams can build a data-driven case for replacement. In one example, a machine repeatedly returned to acceptable condition after intervention, only to quickly degrade again. Over time, this pattern helped the organization recognize that the asset was no longer viable, positioning Augury as a valuable input for machine replacement decisions.

• Application in automated warehouse operations. Another interviewee shared that Augury is beginning to be applied in automated warehouse environments, where the same value proposition of avoiding unplanned downtime is critical. Although the operational context differs from manufacturing, the underlying need is the same: ensuring that automated systems, which are directly tied to customer fulfillment, remain operational. The interviewee emphasized that the same user groups responsible for uptime in production are now leveraging Augury to protect warehouse automation, highlighting the solution’s cross-functional applicability.

Flexibility would also be quantified when evaluated as part of a specific project (described in more detail in Total Economic Impact Approach).