Forging Ahead: Strategic Maintenance in the UK Metals Industry

Like many industries today, the UK metals industry faces a complex landscape of operational challenges and strategic opportunities. The 2025/2026 UK Metal Council's "State of the UK Metals Industry" report delivers the results of a comprehensive survey of industry leaders and provides detailed analysis, identifying key areas that necessitate focused attention and robust solutions. The industry's resilience and capacity for innovation are paramount, given its foundational role across diverse sectors of the UK economy.

After reviewing the report, we were struck by the role that a Computerised Maintenance Management System (CMMS) can provide in addressing these critical issues highlighted in the survey results. To provide a brief overview, we will summarise the five topics that stood out to us and suggest ways that a CMMS can contribute.

1. Managing the Skills Gap and Workforce Retention

The industry confronts a severe talent shortage, with 81% of companies reporting difficulties in recruiting qualified candidates. This challenge is worsened by an aging workforce and a growing emphasis on internal talent development, necessitating effective knowledge transfer and workforce engagement strategies.

A CMMS can significantly contribute to workforce development and retention, including:

• Knowledge Transfer: A CMMS captures institutional knowledge through digital work orders, access to manuals and documentation and Standard Operating Procedures (SOPs). This digital repository facilitates the transfer of expertise and institutional knowledge to new recruits and apprentices, lessening the impact of workforce transitions.
• Employee Engagement: The report highlights the importance of employee well-being and engagement for retention. A CMMS reduces technician stress by optimising work schedules, ensuring the availability of necessary tools and parts, and providing clear task instructions, resulting in a more productive and engaged workforce.

2. Supply Chain Resilience and Traceability

Supply chain disruptions were a significant concern for 36% of businesses and recent world events have reinforced the fragility of global supply chains. Price volatility for raw materials, geopolitical factors, and limited supplier options contribute to this vulnerability. To date, the industry has responded with supplier diversification, collaboration with industry associations, and the establishment of long-term partnerships.

A CMMS can extend those efforts toward supply chain resilience and traceability by offering:

• Significantly improved tracking and reordering of Maintenance, Repair, and Operations (MRO) parts. When integrated with ERP systems, it can also improve purchase order workflow and visibility. Combined, these approaches minimise the risk of production downtime due to critical parts shortages and optimises inventory levels to mitigate stockouts due to lead time challenges.
• Tracking of material flows in recycling-intensive sectors like aluminium and steel to help ensure the quality of secondary raw materials. This capability is crucial for maintaining product integrity and regulatory compliance throughout the supply chain.

3. Energy Efficiency and Cost Management

Energy costs represent one of the most significant concerns for the industry, with 65% of companies identifying high energy consumption as a primary driver of escalating operational expenses. Businesses are actively pursuing strategies such as energy audits and process modifications to mitigate consumption, alongside increasing investment in renewable energy sources.

A CMMS offers capabilities for energy management, including:

• Asset Optimisation: By scheduling and tracking preventive maintenance, a CMMS ensures machinery operates at optimal efficiency, thereby reducing energy waste associated with underperforming or poorly maintained equipment.
• Process Modifications: The report notes an increase in businesses implementing production process modifications to reduce energy consumption. A CMMS can effectively document these equipment modifications, enabling monitoring of their impact on energy usage.

4. Transition to Net Zero and Circular Economy

The industry demonstrates a strong commitment to sustainability, with approximately 47% of respondents dedicated to achieving Net Zero and 40% adopting circular economy practices. This transition necessitates effective strategies for resource management and waste reduction.

A CMMS is a vital tool for advancing Net Zero and circular economy objectives by supporting:

• Asset Longevity: Through automated preventive maintenance scheduling, a CMMS extends the operational lifecycle of critical assets. This directly supports circular economy principles by maximising asset utility and deferring the need for new equipment.
• Regulatory Compliance: As environmental regulations become more stringent, a CMMS provides a centralised repository for all maintenance records. This streamlines audit processes and facilitates comprehensive sustainability reporting, ensuring adherence to evolving environmental standards.

5. Embracing "Industry 4.0" and Digital Technology

The report underscores the growing importance of Industry 4.0 capabilities, which integrate real-time data analytics and digital twins. The metals industry is increasingly adopting digital technologies to enhance competitiveness and operational efficiency.

A modern CMMS plays a key role in the transition to Industry 4.0 adoption by:

• Seamlessly integrating with IoT sensors on the shop floor to enable condition-based maintenance. This facilitates a shift from reactive to predictive maintenance strategies, aligning with the industry's drive for smarter technology utilisation and improved competitiveness.

The challenges identified in the UK Metals Council report are substantial but addressable. By strategically implementing and optimising a comprehensive CMMS, maintenance leaders and technicians can play a pivotal role in strengthening operational efficiency, fostering sustainability, and driving the UK metals industry towards a more resilient and prosperous future.