In this article, David Cullern, Group VP Key Accounts at Rubix, explores how European manufacturers are navigating the challenges of unplanned downtime and highlights the findings of Rubix’s Uptime Index – a health check for the European manufacturing industry.
Uptime is a key performance measure in the manufacturing industry. It directly influences profitability, operational efficiency, and the ability to meet delivery timelines. When unplanned downtime occurs, it increases operational costs, reduces productivity, and risks customer satisfaction. These disruptions can also create knock-on effects across the value chain. Maintaining consistent uptime is therefore critical to the stability of operations and the fulfilment of market demand.
To support manufacturers in strengthening their performance in this area, Rubix developed the Uptime Index, a new initiative designed to measure and benchmark operational continuity.
The first findings place the Uptime Index at 74 out of 100, as of June 2025. While this figure reflects a high level of confidence among European manufacturers, it also signals that improvement is possible. Rubix’s recent whitepaper, Moving in Sync: How Seamless Coordination Drives Uptime, provides further insight into the contributing factors.
Current gaps in integration
Despite confidence in their current levels of uptime, many manufacturers recognise that misalignment between departments and functions can affect performance. The Uptime Index research found that 69 percent of European manufacturers believe integration between procurement, inventory and maintenance could be improved. This disconnection creates inefficiencies, increases the likelihood of disruptions arising in the first place, and makes them more difficult to manage when they do occur.
The whitepaper also found that over a third of manufacturers do not believe their procurement teams fully understand the operational impact of downtime. Where this disconnect exists, it can lead to delays in ordering parts or booking services, ultimately extending the time taken to resolve maintenance issues.
Strengthening collaboration across functions
Improving integration between departments remains a priority for many manufacturers. The research highlights that organisations with close collaboration between procurement, inventory, and maintenance functions tend to perform better in managing downtime and avoiding disruption. These businesses are more likely to hold critical parts in stock, have established relationships with suppliers, and maintain clear communication channels across teams.
Manufacturers also benefit from digital systems that enable cross-functional visibility. Shared platforms that allow real-time tracking of stock, service schedules, and supplier lead times are improving decision-making and enabling more coordinated responses to emerging issues.
Understanding the root causes of downtime
A key finding from the Uptime Index is that 86 percent of manufacturers have experienced an increase in unplanned downtime over the past year. Several factors contribute to this rise.
One major challenge is the availability of spare parts. Many manufacturers report that delays in sourcing essential components are becoming more frequent and are adding pressure to already complex maintenance processes.
Another area of concern is the accuracy of inventory data. Only 43 percent of manufacturers are confident that their current inventory systems can reliably support proactive maintenance planning. Without accurate visibility over stock levels, it becomes more difficult to pre-empt component shortages or respond efficiently to failures.
Skills shortages are also playing a role. Many manufacturers report difficulty recruiting and retaining qualified maintenance staff, which can extend the time needed to address breakdowns and conduct routine servicing.
The importance of proactive maintenance strategies
Despite these challenges, many manufacturers are making progress by adopting more proactive maintenance approaches. The research shows that manufacturers who invest in predictive and preventative maintenance tools experience fewer downtime incidents and report higher levels of operational confidence.
Condition monitoring, for example, is helping organisations to better understand the health of their assets and detect early signs of wear or failure. However, uptake is not yet widespread. Only half of manufacturers report using sensor-based condition monitoring at scale. This suggests that further investment and education could help manufacturers close the gap between current and optimal uptime performance.
External partners play a role in improving uptime
While internal integration is essential, the research also shows that manufacturers are looking externally for support. Over 80 percent of manufacturers agree that specialist suppliers play a vital role in keeping production moving. These partners can provide access to a broader range of products, offer technical advice, and help streamline the procurement process.
To achieve this level of cohesion, Rubix identifies four critical enablers: empowered regional and local leadership that can act within clear strategic guardrails; supplier consolidation to streamline procurement and increase leverage; cross-functional leadership groups that align objectives across departments; and standardised ERP and digital systems to enable consistent visibility of parts, performance, and spend. These elements work together to synchronise operations, eliminate inefficiencies, and ultimately protect uptime.
Rubix’s role in supporting customers includes supplying critical parts, offering technical support, and delivering value-added services such as condition monitoring and predictive maintenance solutions. By working closely with customers, Rubix aims to reduce delays, enhance visibility over parts availability, and ensure production continuity.
Looking ahead
The Uptime Index indicates that European manufacturers are confident in their ability to manage uptime, but also aware of the challenges ahead. As market pressures increase and production schedules become more demanding, manufacturers will need to take further steps to improve operational resilience. This includes investing in digital tools, enhancing cross-functional collaboration, and building stronger relationships with suppliers.
At Rubix, we believe that improving uptime is a continuous process. It requires not only the right tools and technologies, but also the right culture – one that values integration, proactive planning, and knowledge sharing. The Uptime Index will continue to track progress and help manufacturers benchmark their performance as they navigate a changing industrial landscape.
To view the current Uptime Index and download the full whitepaper, please visit www.rubix-group.com/uptime-index.
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