BlueScope saves 2000 hours of downtime with predictive maintenance
Australian steel manufacturer BlueScope says that it has saved around 2000 hours of unplanned downtime across three years at various manufacturing facilities since 2022 by using Siemens’ Senseye predictive maintenance technology. This includes avoiding over 1200 hours of unplanned downtime in Australia and over 750 hours across other sites in New Zealand and South-East Asia.
The shift from reactive to predictive maintenance has also helped prevent 53 complete process interruptions, increase operational efficiency, reduce costs, and minimise production delays and waste across BlueScope’s operations. Senseye combines real-time machine data with AI-driven analytics to detect early signs of equipment degradation, enabling maintenance teams to intervene proactively, before failures occur. The platform is designed to optimise productivity gains for organisations and to streamline processes.
“It’s been great to use digitalisation technology that allows us to predict failures before they even occur, allowing us to act without stopping the lines — minimising waste, emissions and lost productivity,” said Colin Robertson, Digital Transformation Manager for Asset Management at BlueScope. “What started as pilot in 2022 at our home base Springhill Works in Port Kembla quickly evolved into BlueScope becoming one of the early adopters of Senseye’s generative AI functions, which has facilitated knowledge-sharing across our global teams and will continue to support our ambitious digital transformation strategy.
“Senseye Predictive Maintenance has been more than a tool; it’s a catalyst for change in our organisation.”
With unplanned downtime posing major cost and safety risks in the process industry, BlueScope sought a smarter, more forward-looking maintenance approach to protect business continuity and enhance global competitiveness. Siemens and its digital technologies were selected to support this transition, helping BlueScope shift to a data-driven, predictive maintenance model.
“At Siemens, we’re proud to support BlueScope in their digital transformation journey with our Senseye predictive maintenance technology,” said Darryl Kaufmann, Head of Digital Industries for Siemens Australia and New Zealand. “Saving around 2000 hours of unplanned downtime is a powerful example of how AI-driven insights can deliver real operational impact.
“This is a great example of how deploying industrial AI can help manufactures in Australia.”
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