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Why Shutdowns, Turnarounds, and Outages Need a Digital Thread

STOs can consume up to 50% of an annual maintenance budget

Maxime Agnelli / Unsplash

Hexagon Manufacturing Intelligence
Tue, 07/29/2025 - 12:03
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Did you know that shutdowns, turnarounds, and outages (STOs) can consume up to 50% of a plant’s annual maintenance budget? That’s according to a report by the Boston Consulting Group.

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STOs are among the most complex and high-stakes events in industrial operations. They’re costly, especially when executed poorly. But that’s not the only downside. Safety is also a major concern. One survey found, for example, that 40% of plant incidents occur during startups, shutdowns, or shift handovers—making them some of the most hazardous moments in industrial operations.

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