Downtime isn't just inconvenient — it's expensive. Manufacturers lose up to $50 billion a yearopens in a new tab because of it. But what if you could predict problems before they start? That's exactly what predictive service and AI-driven operations help you do — catch issues early and eliminate costly disruptions.
In this article
- Predictive service vs. Preventive maintenance
- Transform your bottom line with predictive service
- Partner with Lexmark for predictive service
- Make your operations more predictable
Predictive service vs. preventive maintenance — what's the difference?
When it comes to caring for your machines, terms like predictive service and preventive maintenance are often confused. Understanding the difference can change the way you protect your business.
Preventive maintenance is often time-based.
Often, manufacturers or service providers structure service contracts to mandate a specific number of visits per year or quarter, irrespective of the actual maintenance needs of the equipment.
Predictive service focuses on the bigger picture.
It examines real-time data and business-critical KPIs to answer the bigger question: "What's at risk if this machine fails?" This approach goes beyond simply replacing parts on a time schedule — it ensures that failures don't interrupt production, delivery, or customer satisfaction. Additionally, it allows you to schedule service at the best time based on the actual usage of the equipment.
| Preventive Maintenance | Predictive Service | |
| Goal | Scheduled maintenance to prevent equipment failure | Prevent service disruptions before they occur |
| Tech | Sensors and basic analytics | Connected devices, IoT platform, machine learning and cloud analytics |
| Timing | Time-based (quarterly, annually, etc.) | Scheduled based on actual device usage in field |
| Impact | Reduces risk of failure (but issues may still be noticed) | Often invisible — problems fixed before impact |
| Scalability | Heavy impact to service personnel when fleets grow | Deploy personnel exactly where and when they are needed |
| Outcome | Longer machine life, fewer breakdowns | Higher uptime, reduced truck rolls and parts usage |
Transform your bottom line with predictive service
Research from IDC shows that only 15% of organizations currently use sensor data and automated service tools to:
- Improve equipment reliability
- Increase operational efficiency
- Cut maintenance costs
- Boost customer satisfaction
When considering connected product solutions, weigh the cost and time of building your own versus using a ready-made platform like Optra IoT. Implementing predictive service sounds complicated because it is — combining IoT, AI, edge computing, and automation is no small task.
But the good news is that you don't have to start from scratch; you can condense what would be a lengthy implementation process into a few weeks.
By implementing Lexmark Optra IoT Solutions, DEXIS experienced noticeable improvements in device uptime and service support. Read their success story.
Partner with Lexmark — don't do it alone
According to Forrester, 58% of businesses lack the internal skills to build these systems. That's where a partner like Lexmark makes all the difference.
We are more than just a vendor — we're manufacturers, too. For over 20 years, we've managed millions of connected devices worldwide. That experience helped us build the Lexmark Optra IoT platform, a full-scale, proven platform designed to seamlessly deploy technology, interpret data, automate actions, and shift your maintenance from reactive to proactive.
- Inventing from scratch is slow, uncertain, and resource heavy. We've already done the heavy lifting
- Finding experts in IoT, AI, and cloud computing is challenging and costly. Our team brings those skills to the table on day one
- Maintaining homegrown software can drain budgets and resources, but Optra's subscription model guarantees ongoing improvements and security without the hassle
Make your operations more predictable today
Nobody likes surprises that slow down business. That's why having a service that's proactive, strategic, and aligned with your company goals matters.
The Lexmark Optra IoT platform:
- Absorbs and analyzes data from your devices and other business systems
- Turns complicated signals into clear insights
- Uses AI and machine learning to stay one step ahead
- Provides dashboards that help you monitor your whole IoT ecosystem
You don't have to do it all now — start small, pilot a few assets, and then build on that success. Get your Optra IoT foundation and your first predictive use case up and running in just three months.
Our partners often see tangible business value within the first year, with performance and ROI improving as you add more use cases. Stop interruptions — start with Optra IoT.
Predictive service FAQ: What you need to know
Q: What is a predictive service?
A: Predictive service uses data and analytics (often AI-driven) to predict when equipment or systems will need maintenance or are at risk of failure. This allows you to fix issues before they cause downtime or costly repairs.
Q: How does predictive service differ from preventive maintenance?
A: Preventive maintenance happens on a set schedule (e.g., every six months), regardless of the machine's actual condition.
Predictive service uses real-time data (sensor readings, telemetry, usage logs, environmental factors) and only alerts you when equipment crosses thresholds and really needs attention.
Q: What are the benefits of predictive service?
A: Some benefits of predictive service include:
- Less downtime and unexpected breakdowns
- Lower maintenance costs by reducing parts costs and truck rolls
- Smarter scheduling of technician visits that saves time and disruption to customers
- Data insights that reveal hidden issues before they escalate
Q: What technologies power predictive service?
A: Predictive service solutions are powered by the following technologies:
- IoT sensors like vibration and temperature
- Telemetry data like actual usage or cycles
- Edge devices for connectivity and data filtering
- Cloud platforms for data ingestion and large-scale modeling
- AI and machine learning to detect anomalies
- APIs that connect to your ERP, CRM or maintenance systems
Q: Which industries benefit most from predictive service?
A: Any manufacturer or field servicer of connected equipment, such as HVAC, medical technology, industrial machinery, office equipment, and heavy equipment, can benefit fewer disruptions and improved equipment reliability.
Some benefits of predictive service include:
- Preventing line stoppages
- Optimizing part replacement
- Ensuring critical devices remain available
- Monitoring fleets and warehousing equipment
- Predicting turbine or transformer issues before outages
Q: How do you get started with predictive service?
A: Getting started with predictive service involves:
- Assessing assets and priorities: identify high-value or failure-prone equipment.
- Deploying sensors selectively: start with a pilot on a small set.
- Establishing data pipelines: ensure secure, reliable transmission to analytics.
- Building or adopting ML models: train on historical and real-time data.
- Integrating with workflows: link alerts to your maintenance management system and schedule technician tasks automatically.
Q: Who can help implement predictive service?
A: Predictive service solutions can be implemented by:
- IoT platform vendors (for sensor-to-cloud solutions)
- System integrators (for end-to-end deployment)
- Data-science consultancies (for custom ML modeling)
- OEM partners (often offer built-in analytics on their equipment)