What if every lost minute in your operations costs tens of thousands of dollars? Today in the industrial world, it is no longer a luxury but necessary to predict and prevent failures. Predictive maintenance, driven by IoT and advanced analytics, promises a revolution in approaching asset management and operational efficiency. For it to promise any good change, those problems pose massive hurdles, preventing many organizations from finishing such steps or having these efforts derailed altogether. Why do such problems persist and how can they best be tackled?
This blog discusses the hurdles in adopting predictive maintenance and how an IoT-powered solution, such as customized platforms from Bridgera, can help overcome those.
The Promise of Predictive Maintenance
Predictive maintenance solutions use IoT sensors combined with AI-driven analytics to focus on minimizing downtime and maintenance costs through optimal asset usage. A predictive maintenance system always tracks critical equipment and identifies anomalies with historical and real-time data patterns, followed by predictions for failure from the same equipment.
For example, consider a 24/7 manufacturing company. Downtime can cost thousands of dollars per minute. Predictive maintenance will allow the company to predict a breakdown in a conveyor belt or motor and schedule repairs at the most opportune time.
The global predictive maintenance market was valued at $10.93 billion in 2024 and is expected to grow from $13.65 billion in 2025 to $70.73 billion by 2032, growing at a CAGR of 26.5% during the forecast period.
Common Challenges in Predictive Maintenance Implementation
1. Data Integration Across Systems
One major challenge is integrating with other systems. Most companies run on a patchwork of legacy systems, and data consolidation becomes somewhat challenging for actionable insights. The non-standardization of devices and platforms worsens the situation.
Solution: Bridgera’s IoT platform seamlessly integrates with SCADA systems, PLCs, and other industrial control systems. Bridgera simplifies data consolidation by offering a unified view of data from disparate sources, ensuring compatibility with both legacy and modern infrastructure.
2. High Implementation Costs
Predictive maintenance systems often require a large upfront investment in IoT devices, analytics software, and skilled personnel, which can be too expensive for small and medium enterprises.
Solution: Bridgera provides white-label IoT solutions that cut the entry barriers. The scalable price models allow one to start with small and go large as and when required, hence predictive maintenance being within reach and not requiring gigantic upfront investments. In addition, Bridgera’s tailor-made approach allows cost-effectiveness since it filters out unnecessary features and focuses solely on the requirements of the client.
3. Data Overload and Poor Analytics
Since the generation of enormous volumes of data in IoT sensors does not lead companies to understand such data, there arises a failure of the full power of predictive maintenance systems without solid analytics capabilities.
Solution: Bridgera uses AI and machine learning algorithms to process massive datasets efficiently. Its platform helps businesses focus on the key metrics that matter, like equipment health scores and failure probabilities, removing noise and emphasizing actionable insights. The advanced dashboarding capabilities ensure that stakeholders can easily interpret and act on the data.
4. Resistance to Change
Implementing predictive maintenance requires cultural and operational shifts, which often receive resistance from employees who are used to the old ways. This slows down the adoption process and reduces the effectiveness of the system.
Solution: Bridgera does not only provide technology but also end-to-end support, including training programs and stakeholder engagement strategies. It helps teams understand the value of predictive maintenance, ensuring smooth adoption and aligning the solution with the organization’s operational goals.
5. Lack of Skilled Personnel
Predictive maintenance systems need adept people who will manage the devices within the IoT, interpret data, and make decisions appropriately. However, finding such talent is rather challenging for most organizations, and retaining them has also proven challenging.
Solution: Bridgera solves this problem by offering managed IoT services. Companies can outsource everything from the configuration of devices to data analytics to the experts at Bridgera so that the internal teams can focus on core operations. Bridgera’s platform also offers user-friendly interfaces that make it easy for non-technical staff to interpret data.
6. Security Concerns
New vulnerabilities open with the adoption of IoT devices. Predictive maintenance systems, hence, can become a potential cyberattack target if sensitive operational data is not protected.
Solution: Bridgera prioritizes security with end-to-end data protection, which includes encryption, secure cloud storage, and network safeguards. Bridgera, therefore, aligns with the industry standards in ensuring reliable protection against cyber threats.
The Bridgera Advantage
Bridgera’s predictive maintenance solutions address these challenges head-on, offering:
- Customizable IoT Solutions: The offerings of Bridgera go according to the needs of every specific industry, from manufacturing to healthcare and oil & gas.
- Seamless Integration: Bridgera’s platform ensures that its IoT connectivity is not a stumbling block to legacy system integration, thus bringing about smooth predictive maintenance.
- Actionable Insights: Advanced analytics capability is used by businesses with actionable insights to help reduce information overload.
- Cost-Effective Models: Our scalable pricing helps companies of all sizes benefit from predictive maintenance.
- Security and Compliance: Robust IoT security features protect sensitive operational data, ensuring trust and reliability.
- Comprehensive Support: Bridgera provides end-to-end services, from IoT implementation to training and ongoing support.
The Future of Predictive Maintenance
Predictive maintenance will also become more available and effective with the advancement of IoT technology. Emerging technologies like edge computing, 5G, and digital twins will take predictive maintenance to a new level, making these solutions indispensable to industries that will have to compete in an increasingly competitive future.
Bridgera is pioneering this revolution, and by leading the way into innovative solutions, it enables businesses to overcome challenges in implementation to unleash the complete potential of predictive maintenance.
Bottomline
Predictive maintenance has the potential to transform operations and reduce costs, but successful implementation requires strategic planning and a robust platform. Partnering with Bridgera empowers organizations to overcome challenges seamlessly, leveraging cutting-edge IoT solutions to utilize the full benefits of predictive maintenance and drive sustainable growth.
With Bridgera, simplify Predictive Maintenance implementation to drive operational excellence and future-ready innovation.
About Bridgera: Bridgera effortlessly combines innovation and expertise to deliver cutting-edge solutions using connected intelligence. We engineer experiences that go beyond expectations, equipping our clients with the tools they need to excel in an increasingly interconnected world. Since our establishment in 2015, Bridgera, headquartered in Raleigh, NC, has specialized in crafting and managing tailored SaaS solutions for web, mobile, and IoT applications across North America. 
About Author: Gayatri Sriaadhibhatla is a seasoned writer with a diverse portfolio spanning multiple industries. Her passion for technology and a keen interest in emerging IoT trends drive her writing pursuits. Always eager to expand her knowledge, she is dedicated to delivering insightful content that informs the audience.
