#United States #New York #Copia Automation #Industrial DevOps #Downtime Costs

Copia Automation’s Eye-Opening Report on Downtime Costs

In a bold revelation, Copia Automation, a leader in Industrial Code Lifecycle Management (ICLM), has published its 2nd Annual State of Industrial DevOps Report, unveiling staggering findings about downtime costs across different management levels within industrial organizations. The numbers are staggering, with average hourly downtime costs jumping to $4.29 million for C-Suite executives—51% higher than the average reported by operational managers.

The report surveyed 200 senior leaders in the industrial sector and painted a stark picture of a burgeoning gap in perception regarding the causes and costs of downtime. This disconnect not only poses a challenge for organizational alignment but also represents a strategic blind spot that leaves companies vulnerable to severe risks. While executives cite 52% of downtime caused by issues related to industrial code, operational managers attribute only about 30% of downtime to the same source, often focusing instead on hardware malfunctions and human error.

As the report highlights, the fear of cybersecurity breaches is taken far more seriously by those in the C-Suite (45% consider it a top concern) than by managers (only 22% indicate it as a significant issue). This discrepancy underlines the need for clearer communication and alignment between upper management and operational teams to ensure that vital issues are given the attention they deserve.

Adam Gluck, CEO and Founder of Copia Automation, shared insights on the ramifications of this gap: “A robust Industrial Code Lifecycle Management platform provides the single source of truth needed to close that gap and align the entire organization on both risks and solutions.” Addressing the perception gap is crucial for fostering an organization that can move swiftly in the face of industrial challenges, especially as Industrial DevOps gains momentum—92% of organizations are already investing in or planning to adopt this model.

In addition to revealing these alarming gaps, the report identified several key trends indicative of how the industrial sector is evolving. For instance:

• - AI Paradox: While 89% of decision-makers believe that AI will enhance efficiencies, leaders remain concerned about data security (cited by 40%), while managers express a preference for immediate tactical features.
• - The Expanding Attack Surface: Firms are now managing more than 2,000 PLCs and an additional 2,100 devices, creating complex operational ecosystems that require intelligent solutions.
• - Unified Planning: A striking 87% of leaders emphasize the need for integrating OT cybersecurity tools with industrial code management, pointing to a unified approach for managing risks in today's complex environments.
• - Human Change Management Resistance is identified as the leading barrier to adoption, surpassing budgetary constraints and competing priorities.

The report serves as a crucial warning for companies navigating the industrial landscape, particularly as they involve themselves deeper in Industrial DevOps. The advice from industry leaders, including Sebastián Trolli and Jeff Winter, emphasizes the imminent need for businesses to modernize their approaches to managing the intricacies of industrial automation code. To thrive, organizations must prioritize creating standardized solutions and investing in long-term resilience over short-term fixes.

The complete 2025 State of Industrial DevOps Report offers valuable data and includes a five-step playbook for assessing maturity levels in embracing these evolving standards. Insights from this report could prove critical for organizations aiming to remain competitive in a rapidly changing industrial environment.

For additional information, the entire report can be downloaded directly from Copia Automation's website. As organizations look to adapt to contemporary challenges, such resources promise invaluable guidance for ensuring robust operations and longevity in the age of AI.