BlueScope saves ~2,000 hours of downtime with predictive maintenance technology

Increased efficiency and minimised production delays and waste

BlueScope, a global leader in steel manufacturing based in Australia, with plants in New Zealand, China, Southeast Asia and North America, has saved ~2,000 hours of unplanned downtime across three years at various manufacturing facilities since 2022 by using Siemens’ Senseye predictive maintenance technology. This includes avoiding over 1,200 hours of unplanned downtime in Australia and over 750 hours across other sites in New Zealand and Southeast Asia.

The shift from reactive to predictive maintenance has also helped prevent 53 complete process interruptions, increase operational efficiency, reduce costs, and minimise production delays and waste across BlueScope’s operations. Senseye combines real-time machine data with artificial intelligence (AI)-driven analytics to detect early signs of equipment degradation, enabling maintenance teams to intervene proactively, before failures occur. The platform optimises productivity gains for organisations streamlining processes.

From left to right: Richard Ella - Digitalization Consultant at Siemens, Stojanka Naumoski - Digital Transformation Co-ordinator at BlueScope, Colin Robertson - Digital Transformation Manager for Asset Management at BlueScope, and Chris Wonson - Predictive Maintenance Lead at BlueScope

Colin Robertson, Digital Transformation Manager for Asset Management at BlueScope said, “It’s been great to use digitalisation technology that allows us to predict failures before they even occur, allowing us to act without stopping the lines — minimising waste, emissions, and lost productivity. What started as pilot in 2022 at our home base Springhill Works in Port Kembla quickly evolved into BlueScope becoming one of the early adopters of Senseye’s generative AI functions that’s facilitating knowledge sharing across our global teams and will continue to support our ambitious digital transformation strategy."

Senseye Predictive Maintenance has been more than a tool, it’s a catalyst for change in our organisation. With Siemens as a partner, we are technically and strategically well-positioned for the future.

Colin Robertson, Digital Transformation Manager for Asset Management at BlueScope

With unplanned downtime posing major cost and safety risks in the process industry, BlueScope sought a smarter, more forward-looking maintenance approach to protect business continuity and enhance global competitiveness. Siemens and its digital technologies were selected to support this transition, helping BlueScope shift to a data-driven, predictive maintenance model.

Darryl Kaufmann, Head of Digital Industries for Siemens Australia and New Zealand said, “At Siemens, we’re proud to support BlueScope in their digital transformation journey with our Senseye predictive maintenance technology. Saving around 2,000 hours of unplanned downtime is a powerful example of how AI-driven insights can deliver real operational impact.

By enabling smarter, data-led maintenance strategies, we’re helping our customers like BlueScope reduce waste and emissions, improve efficiency, and strengthen their global competitiveness. This is a great example of how deploying Industrial AI can help manufactures in Australia.

Darryl Kaufmann, Head of Digital Industries for Siemens Australia and New Zealand