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New Copia Automation Report Reveals $4.29M/Hour Downtime Cost for C-Suite, Exposing Critical "Perception Gap" with Plant Floor

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NEW YORK, July 30, 2025 ~ Copia Automation, a leading company in Industrial Code Lifecycle Management (ICLM), has recently released its 2nd Annual State of Industrial DevOps Report. This comprehensive study, which surveyed 200 senior industrial leaders, reveals that the industry is at a clear tipping point with regards to adopting Industrial DevOps. According to the report, 92% of organizations are either already invested in or actively planning to adopt Industrial DevOps. However, this momentum is threatened by a critical "perception gap" between senior executives and operational managers on the true cost and causes of downtime.

The report found that the overall average cost of downtime is a staggering $3.63 million per hour. However, there is a significant difference between the C-Suite and operational managers when it comes to downtime costs. The C-Suite reported an average cost of $4.29 million per hour, which is 51% higher than the average reported by managers ($2.84 million per hour). This gap also extends to the root causes of disruptions. While the C-Suite attributes over half (52%) of all downtime to industrial code issues, operational managers see code as a much smaller factor (30%), pointing more frequently to hardware malfunctions and human error.

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The issue of cybersecurity breaches also highlights this divide, with it being a top concern for the C-Suite (45%) but not as much for managers (22%). According to Sebastián Trolli from Frost & Sullivan, "Fragmented tools are no match for cyber-physical complexity." This emphasizes the need for a unified approach in managing industrial code.

Adam Gluck, CEO and Founder of Copia Automation, stated that "this year's report reveals a crucial insight: while the adoption of Industrial DevOps is accelerating, a hidden 'perception gap' across leadership tiers can silently sabotage progress." He further explains that if there is misalignment between senior executives and operational managers on the risks and solutions related to code and cyber risk, it can greatly hinder progress. Gluck believes that a robust Industrial Code Lifecycle Management platform can bridge this gap and align the entire organization.

The report also shows that the market is rapidly moving towards standardizing its approach to managing complex code in modern manufacturing. According to Sebastián Trolli, "the 2nd Annual State of Industrial DevOps Report signals a tipping point" with 92% of manufacturers committed to adopting Industrial DevOps within the next year.

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Jeff Winter, Vice President of Business Strategy at Critical Manufacturing and a contributing analyst and editor for this report, commented on the operational implications of the findings. He stated that while there is heavy reliance on ad-hoc fixes to solve immediate problems, it creates a cycle of technical debt. Winter believes that investing in solutions that enhance long-term value is crucial for the industry's move towards Industrial DevOps.

The report also highlights other key findings such as the AI paradox, where leaders are focused on strategic risk while managers prioritize tactical features like code optimization. It also reveals that the average enterprise now manages over 2,000 PLCs and another 2,100 associated devices, creating a crisis of scale. The need for a unified platform is reinforced by 87% of leaders who believe it is important to integrate OT cybersecurity tools with industrial code management tools.

However, the report also identifies change management resistance as the top barrier to adoption (43%), surpassing budget (26%) and competing priorities (32%). The full 2025 State of Industrial DevOps Report provides a detailed analysis of these trends and offers a five-step playbook for organizations to benchmark their own maturity using the wealth of benchmark data within this report.

The full report is available for download on Copia Automation's website. As more organizations recognize the importance of Industrial DevOps in managing complex code and mitigating risks, it is clear that standardization and alignment across all levels of leadership are crucial for success in the industry.
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