Maintenance Repair Operations for Automation Solutions

Global Maintenance Repair Operations for Automation Solutions Market to Reach US$152.9 Billion by 2030

The global market for Maintenance Repair Operations for Automation Solutions estimated at US$99.1 Billion in the year 2024, is expected to reach US$152.9 Billion by 2030, growing at a CAGR of 7.5% over the analysis period 2024-2030. MRO Products, one of the segments analyzed in the report, is expected to record a 6.0% CAGR and reach US$91.8 Billion by the end of the analysis period. Growth in the MRO Services segment is estimated at 10.0% CAGR over the analysis period.

The U.S. Market is Estimated at US$27.0 Billion While China is Forecast to Grow at 11.5% CAGR

The Maintenance Repair Operations for Automation Solutions market in the U.S. is estimated at US$27.0 Billion in the year 2024. China, the world`s second largest economy, is forecast to reach a projected market size of US$31.9 Billion by the year 2030 trailing a CAGR of 11.5% over the analysis period 2024-2030. Among the other noteworthy geographic markets are Japan and Canada, each forecast to grow at a CAGR of 3.9% and 7.1% respectively over the analysis period. Within Europe, Germany is forecast to grow at approximately 4.9% CAGR.

Global Maintenance Repair Operations for Automation Solutions Market – Key Trends & Drivers Summarized

Why Is Maintenance Repair Operations (MRO) Crucial for Sustaining Automation Investments?

Maintenance Repair Operations (MRO) for automation solutions has emerged as a critical function for ensuring the longevity, safety, and performance of automated systems across industrial sectors. As companies invest in robotics, programmable logic controllers, motion control systems, and smart sensors to enhance productivity, the need to maintain these high-value assets becomes increasingly important. MRO in this context encompasses the regular upkeep, diagnostics, spare parts management, calibration, and emergency repairs required to prevent system failures and production downtime. Without a robust MRO strategy, even the most advanced automation systems risk underperformance, reduced efficiency, or total operational halts. Many facilities now rely on tightly integrated networks of machines and control systems, meaning that the failure of one component can trigger cascading disruptions throughout the line. This makes preventive maintenance and condition monitoring essential. Companies in automotive manufacturing, electronics, pharmaceuticals, food processing, and logistics are placing greater emphasis on structured MRO practices to protect their automation investments. Downtime in these environments can result in significant revenue loss and compromised quality, making reliability a top priority. MRO is also central to regulatory compliance, especially in sectors where safety standards and traceability requirements are high. As automation spreads into more industries and use cases, MRO is no longer a background activity but a strategic imperative that supports uninterrupted production and competitive advantage.

How Is Technology Enhancing the Efficiency and Scope of MRO in Automation Systems?

The rise of digital technologies is dramatically transforming how MRO is conducted within the automation ecosystem. Predictive maintenance, powered by sensors and data analytics, is allowing facilities to identify wear and tear in machinery before breakdowns occur, thus minimizing unexpected disruptions. The integration of Industrial Internet of Things (IIoT) devices enables continuous real-time monitoring of automation systems, providing insights into temperature, vibration, pressure, and other critical parameters. Artificial intelligence and machine learning algorithms process this data to forecast maintenance needs and suggest optimized intervention schedules. Augmented reality and remote support tools are also being deployed to guide on-site technicians through complex repairs with visual overlays and step-by-step instructions. Digital twins of automated systems allow engineers to simulate wear patterns, test repair scenarios, and improve designs based on field data. Cloud-based asset management platforms centralize MRO records, spare parts inventories, and service history, improving decision-making and reducing the time spent on paperwork. 3D printing is being used to produce hard-to-find or custom replacement parts on demand, shortening lead times and reducing dependence on large inventories. Automation companies are embedding self-diagnostic capabilities into new equipment, allowing for early fault detection and remote troubleshooting. These advancements are not only enhancing the speed and accuracy of maintenance operations but are also redefining the skill sets required for MRO professionals. As technology continues to evolve, the MRO function is becoming more proactive, data-driven, and essential to maximizing the value of automation investments.

What Industry and Operational Trends Are Shaping the Demand for MRO in Automated Environments?

A series of broad industry trends are reshaping the way organizations approach MRO for their automation systems. One of the most significant is the shift toward lean manufacturing and just-in-time production, which leaves little room for downtime and necessitates highly reliable machinery. As factories become more reliant on automated systems to maintain throughput, the demand for timely and effective MRO has intensified. The globalization of manufacturing and the expansion of supply chains have also increased the complexity of maintenance operations, requiring coordination across multiple sites and vendors. There is growing pressure to reduce the total cost of ownership for automated assets, and efficient MRO practices are key to extending equipment lifecycles and avoiding costly replacements. Sustainability initiatives are encouraging facilities to repair and refurbish components rather than discard them, leading to more strategic maintenance planning. Labor shortages and the retirement of experienced technicians are prompting companies to invest in training programs and user-friendly diagnostic tools that reduce reliance on specialized expertise. In sectors like aerospace, oil and gas, and pharmaceuticals, strict compliance and auditability requirements mean MRO processes must be meticulously documented and traceable. The trend toward smart factories and digital transformation is also leading to more integrated and intelligent MRO workflows. Facilities now expect maintenance systems to interact seamlessly with production data, enterprise resource planning software, and inventory controls. These shifts are transforming MRO into a more strategic, collaborative, and technologically sophisticated discipline within modern industrial operations.

What Factors Are Driving Growth in the Global MRO Market for Automation Solutions?

The growth in the global Maintenance Repair Operations market for automation solutions is driven by several converging factors tied to operational efficiency, digital transformation, and industrial resilience. The rapid adoption of automation technologies across sectors such as manufacturing, logistics, healthcare, and energy is increasing the installed base of equipment that requires regular and specialized maintenance. As companies strive to maintain high levels of uptime and performance, investment in predictive maintenance tools and service partnerships is rising. The proliferation of Industry 4.0 and smart factory initiatives is also pushing organizations to integrate MRO into their broader digital ecosystems, ensuring that maintenance becomes a continuous and optimized function rather than a reactive one. Global supply chain volatility and lessons learned from recent disruptions have made asset reliability a key focus, fueling demand for well-orchestrated MRO strategies that prevent costly downtimes. The increasing complexity of automated systems is making in-house maintenance more challenging, prompting many firms to outsource MRO services to specialized vendors with domain expertise. Additionally, aging industrial infrastructure in developed economies is creating a backlog of equipment that needs repair and refurbishment, further boosting the market. Regulatory mandates for equipment safety, environmental compliance, and worker protection are reinforcing the importance of standardized and traceable maintenance procedures. The rise of outcome-based service models, where vendors guarantee uptime and performance metrics, is also encouraging broader adoption of MRO programs. Combined, these drivers point to sustained and expanding demand for robust MRO solutions that ensure automation technologies deliver consistent, long-term value across industries.

SCOPE OF STUDY:

The report analyzes the Maintenance Repair Operations for Automation Solutions market in terms of units by the following Segments, and Geographic Regions/Countries:

Segments:
Type (MRO Products, MRO Services); Application (Preventive Maintenance Application, Predictive Maintenance Application, Corrective Maintenance Application); End-Use (Process Industries End-Use, Discrete Industries End-Use)

Geographic Regions/Countries:
World; United States; Canada; Japan; China; Europe (France; Germany; Italy; United Kingdom; Spain; Russia; and Rest of Europe); Asia-Pacific (Australia; India; South Korea; and Rest of Asia-Pacific); Latin America (Argentina; Brazil; Mexico; and Rest of Latin America); Middle East (Iran; Israel; Saudi Arabia; United Arab Emirates; and Rest of Middle East); and Africa.

Select Competitors (Total 42 Featured) -

• ABB Ltd.
• Ametek, Inc.
• Bilfinger SE
• Danaher Corp.
• Emerson Electric Co.
• Endress+Hauser Group
• FANUC Corp.
• Festo SE & Co. KG
• GE (General Electric)
• Honeywell International Inc.
• IMI Plc
• Mitsubishi Electric Corp.
• Omron Corp.
• Rexel
• Rockwell Automation Inc.
• SICK AG
• Schneider Electric SE
• Siemens AG
• Toshiba Corp.
• WESCO International, Inc.
• W.W. Grainger, Inc.
• Wood plc (MRO services)
• Yokogawa Electric Corp.

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