Skilled Workers Wanted: A New Perspective on the Manufacturing Labor Gap

What if we told you the skilled labor shortage in manufacturing isn't just a crisis to manage but a chance to transform your operations for the better?

MaintainX’s State of Industrial Maintenance Report 2024 digs deep into today's industrial maintenance landscape, uncovering trends such as the downtime paradox and the preventive maintenance gap. While we found that the skilled labor shortage is still a big problem, we also discovered creative steps companies are taking to overcome this hurdle.

In this post, we'll walk you through our findings. Discover the factors fueling the skilled labor shortage, the risks of inaction, and, most importantly, concrete steps you can take to combat the shortage. We’ll show you how adapting quickly won’t just help you weather the labor gap, but propel your maintenance operations to the next level. Ready to dive in? Let's get started.

Why it matters: The real impact of the skilled labor shortage

60% of respondents tell us the skilled labor shortage is a major challenge in improving their maintenance programs.

“There’s not as many young people coming into maintenance as there used to be years ago,” explains Woody Rogers, the Maintenance Supervisor at Cintas. “In some cases, we don’t even get a single application when a maintenance role opens up. And when we do get applications, they don’t always have the required skills.”

The problem is only going to get worse: According to a recent report by Deloitte and the Manufacturing Institute, 1.9 million jobs in manufacturing could remain unfilled by 2033 due to the skills gap. “As the older generations retire, it’s becoming challenging to replace that human capital,” says Justin Float, Fleet Maintenance Manager at Herlache Truck Lines. “The younger generations don’t grow up dreaming of becoming mechanics.”

But what does this actually mean for manufacturing? Let’s consider a few practical effects.

1. Reduced operational efficiency

Without enough staff, organizations will struggle to maintain their equipment and systems. Imagine a facility where multiple assets go down at once without enough qualified maintenance technicians to fix them. They’ll end up with delayed repairs and a maintenance backlog, especially if some of these machines are critical. This can create a ripple effect, like missed production deadlines or slower fulfillment times. Ultimately, the facility will have to deal with revenue losses and unhappy customers.

2. Compromised safety

It’s not just the extended downtime that’s a problem. Having limited labor means increasing the workload of the staff you do have. If such technicians get overworked, the quality of their work will suffer. This may result in equipment failures, safety hazards, or even production shutdowns. These issues can further decrease productivity and create costly disruptions.

3. Stifled innovation

A lack of skilled workers hinders a company’s ability to innovate and adopt new technologies. For example, imagine a factory looking to implement predictive maintenance with IoT sensors and advanced software. Without experienced personnel who understand the equipment and technology, the facility will struggle. This can leave the company at a competitive disadvantage—especially compared to rivals who are better equipped to implement advanced solutions.

How to tackle the skilled labor shortage

To overcome the skilled labor shortage, manufacturers must rethink how they acquire and develop talent. Rather than viewing it as an impossible challenge, companies can turn it into an opportunity. Here are some targeted strategies we suggest:

Enhance training programs

Without a steady pipeline of new staff, you need to ensure your existing workers gain the necessary skills to stay ahead. Investing in robust, frequent training is one of the most effective ways to do this. Think of this as an opportunity to elevate your team's skills beyond the status quo. Because your existing team already understands your processes, you can drive innovation from within. This proactive approach doesn’t just fill skill gaps—it transforms your workforce into a competitive advantage.

This approach is already front and center at companies like Cintas. “We’re creating videos for each preventive maintenance task,” says Woody Rogers, Maintenance Supervisor at Cintas. “Any team member can easily follow the work order and complete the task with standardized precision.”

Outsource specialized tasks

To get the best out of your staff, outsource some of your labor needs. By delegating some maintenance work to external experts, you can achieve two things. First, you can ensure the work gets done with a level of expertise that you lack in-house. Second, you can free up time for your existing staff to focus on higher-value activities that drive innovation and improve productivity. 

Provide on-the-job mentorship

Companies can also address the evolving labor landscape by developing internal pipelines of skilled technicians. Instead of relying entirely on an external pipeline, you can foster learning environments where experienced professionals mentor new recruits. Some teams—like Cintas—are already putting this into practice. “We want to play an active role in developing the skilled workforce we need to meet the evolving needs of our organization,” says Woody Rogers.

Invest in tools that boost efficiency

Dealing with a labor shortage means you must optimize efficiency for the staff you do have. One key step is to enhance their productivity by automating and streamlining tedious maintenance processes. Implementing modern technology, such as a Computerized Maintenance Management System (CMMS), can significantly reduce manual tasks and improve workflow efficiency.

A CMMS frees up valuable time for your technicians by automating routine maintenance scheduling, tracking work orders, and managing inventory. This lets your team concentrate on what they do best: keeping operations running smoothly and efficiently while minimizing downtime.

Build a future-ready workforce

The ongoing labor shortage makes one thing clear: Companies must become more proactive and think outside the box to ensure a steady talent pipeline. Investing in training, freeing up critical time for your staff by outsourcing specialized tasks, and cultivating talent from within will help your team stay competitive and motivated.

Think of these steps not simply as one-off actions but as fundamental parts of your business strategy as you move forward. As a leader, you need to champion these initiatives and make them central to your company’s culture. When managers invest in upskilling and creative solutions, they not only build a stronger, more capable team but also ensure the company is prepared to meet tomorrow’s demands.

Get creative and proactively seek solutions, and you’ll set yourself on the path to creating a more robust, resilient workforce. By adapting quickly, you can manage the effects of the labor shortage and position yourself to thrive in an increasingly competitive environment.

Want to get the full insights? Download the report today.

The State of Industrial Maintenance report contains exclusive insights from 1,200 maintenance, repair, and operations (MRO) professionals about the ever-evolving maintenance landscape. Download the full report to discover the key trends shaping industrial maintenance in 2024 and beyond, including:

• The top threat to undisrupted operations.
• Strategies top-performing facilities use to address skilled labor shortages.
• The surprising gap between preventive maintenance implementation and adoption.
• Key metrics and KPIs that facilities commonly monitor to measure performance.

Don't let your facility fall behind. Equip yourself with data-driven strategies to optimize maintenance, lower costs, and enhance efficiency.