
Can a manufacturing plant really shut down because of a 2-cent part?
In American terms, we’re talking about a two-cent part. In South Africa, that would be about 33 cents.
Now, a few weeks ago, I came across an interesting article in Industry Week with the headline: “The Two-Cent Part That Shut Down a Factory for a Month.”
It was written by Michael Podgortsev, a director of data and AI strategy and former CTO.
I’ve included a link to the original article at the bottom of this post.
And yes, it is possible to have a manufacturing plant shut down for an extended period because of a part costing next to nothing.
The argument Podgortsev makes is an interesting one. Predictive maintenance systems are designed to identify potential failures before they happen. But there is a problem. These systems tend to concentrate on components that wear out regularly, because those are the parts engineers expect to fail.
The trouble is that a factory can be brought to its knees by a component that rarely fails and is therefore not monitored.
A two-cent bolt, for example.
The point is that the cost of a component has very little to do with the cost of a breakdown. The bolt may cost next to nothing, but if its failure brings a production line to a standstill, the consequences can be enormous.
A factory can lose weeks of production because of something nobody thought was worth monitoring.
And that’s the problem with predictive maintenance. It may be very good at predicting the failures it has been designed to detect, but what about the ones nobody thought about?
Why I’m interested in predictive maintenance
You might be wondering why I’m taking an interest in this.
Well, I began writing about industrial automation for a large European automation manufacturer way back in 1996.
I spent many years with that company, writing about its products and systems, the automation of factories and the arrival of new predictive-maintenance technologies. That continued for about 25 years.
So you can understand why I still take an interest in what is happening in industrial automation. I came across the Industry Week article and found it fascinating.
It also reminded me of how much the technology has advanced over the years.
Industrial automation has become an enormous industry, with a large number of players in the United States and here in South Africa. And now artificial intelligence is being incorporated into predictive-maintenance systems to help manufacturers identify potential problems before they bring production to a halt.
There is a lot of technology involved, from sensors and monitoring equipment to software, data analytics and AI.
But the underlying objective is quite simple.
Keep the factory running.
The players in the market
There are numerous companies in the United States developing and supplying industrial automation and predictive-maintenance technology.
Some specialise in machine-health monitoring and AI-driven predictive maintenance. Others are the large automation and industrial software companies that incorporate these technologies into their broader systems.
Among the American players are companies such as Tractian, Augury, MultiSensor AI, GE Vernova, IBM, Emerson, Rockwell Automation and Honeywell.
Then there are companies such as C3 AI and SymphonyAI Industrial, which develop AI-based systems for industrial applications.
And this is not just an American story.
The major European automation companies, including ABB and Siemens, have been developing predictive-maintenance systems for years. They are also active in the American market and have a substantial presence in South Africa.
Here, the market includes local specialists as well as the South African operations of the international automation companies.
Companies such as GrowthTech Development House, Probe Integrated Mining Technologies, 4Sight Operational Technologies and Boazmatics are involved in various aspects of industrial technology, AI, monitoring and predictive maintenance.
There are also companies such as Process Automation, which works with Razor Labs’ DataMind AI predictive-maintenance platform in the African market.
And then, of course, there are ABB, Siemens, Schneider Electric and Rockwell Automation, all of which have a presence in South Africa and offer automation and predictive-maintenance solutions.
This is a substantial industry, and there is plenty of technology available to manufacturers looking to reduce downtime and improve the reliability of their operations.
The problem with downtime
Downtime is something any factory manager and company director fears.
Imagine having a manufacturing plant shut down for a month.
The loss of revenue could be substantial. There are production schedules to meet, customers waiting for deliveries and employees who still have to be paid.
And depending on the industry, the consequences can extend well beyond the factory itself.
This is why manufacturers have invested so heavily in automation, monitoring and predictive maintenance.
The idea is to identify problems before they become serious enough to stop production.
AI is now helping to improve these systems by analysing data from machinery, identifying unusual patterns and warning operators of potential failures.
But the two-cent part raises an important question.
What happens when the system doesn’t identify the problem?
Incidentally, the Cape Town Manufacturing Summit 2026 is taking place at the Cape Town International Convention Centre on 11 November.
It’s a one-day event covering a range of manufacturing topics, including automation, digital transformation, sustainability and skills development. There will also be an exhibition of machinery and industrial technologies.
I mention it because automation is very much part of the manufacturing industry’s ongoing development, and it ties in with the subject of this article.
And what about the two-cent part?
So will it be a two-cent part that brings a factory to a standstill?
In South Africa, we’re talking about approximately 33 cents.
Predictive maintenance can be an enormous help to manufacturers. But no matter how sophisticated the system, there are always going to be gaps.
There are technological and automation elements involved in controlling and monitoring machinery, but the problem is that no system can necessarily anticipate every possible failure.
And that is where the risk assessment comes in.
Manufacturers need to consider not only the components that are expected to fail regularly, but also those rare failures that could have serious consequences.
Because the cost of the part may be negligible.
The cost of shutting down the factory is another matter altogether.
Further reading
The Two-Cent Part That Shut Down a Factory for a Month — Michael Podgortsev, Industry Week.
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