Sustaining Success: Proactive Maintenance for Long-Term Performance

The true value of an Operational Technology (OT) modernization project is realized long after the go-live date. Ongoing maintenance and optimization are essential to sustaining the health, security, and performance of modernized systems. This phase focuses on building a methodology and culture of proactive maintenance, embedding the practices, tools, and mindset needed to protect your investment and sustain long-term operational performance. 

Enabling a Culture of Proactive Maintenance

The Run & Maintain phase marks the shift from maximizing uptime and production. Instead of resolving issues that disrupt production, proactive maintenance anticipates problems before they occur. This approach is enabled by Champion’s 24UP® Solutions, which combine continuous monitoring, analytics, and targeted improvement strategies. 

• Condition-Based Monitoring: 24UP® implements real-time monitoring of system performance and health. Using data analytics, early signs of degradation are detected, allowing for condition-based maintenance and eliminating costly unplanned downtime. 
• Reliability-Centered Maintenance (RCM): Maintenance activities are prioritized by asset criticality and failure risk, ensuring resources focus on the systems most vital to safety, production, and compliance. Data from control systems, historians, and sensors supports reliability metrics to guide decisions. 
• Continuous Improvement: Maintenance doesn’t mean standing still. Through 24UP®, opportunities are continually identified to optimize control strategies, enhance efficiency, and introduce new features that drive added value from your assets. 

Sustaining Security, Compliance & Performance

A modernized system is only as secure and sustainable as its maintenance program. With evolving cyber threats, regulatory requirements, and technology changes, sustaining reliability requires continuous vigilance and structured lifecycle management. 

• Vulnerability & Patch Management: 24UP®  enables a disciplined process for vulnerability scanning and patch deployment, tailored specifically for OT environments. Systems remain secure and compliant without disrupting critical operations. 
• Compliance & Configuration Management: Regular audits confirm alignment with ISA/IEC 62443, NIST CSF, and corporate cybersecurity policies. Configuration backups, user-access reviews, and change-control logs ensure the environment remains both secure and supportable. 
• Lifecycle & Obsolescence Planning: Clear visibility into hardware and software lifecycles allows for proactive planning of upgrades and replacements, reducing exposure to unsupported technologies and avoiding last-minute procurement challenges. 
• Spare Parts & Asset Health Management: 24UP®  tracks asset condition and spare-inventory status, helping facilities avoid downtime due to unavailability of critical components. 

Integrating People, Process & Technology 

Technology alone doesn’t sustain performance, people do. Champion’s maintenance approach aligns operators, engineers, and maintenance staff around shared visibility and accountability. 

• Operator Training & Knowledge Retention: Continuous upskilling ensures operators remain confident with modern interfaces and procedures, strengthening both safety and performance. 
• Collaboration & Knowledge Capture: Maintenance activities and troubleshooting insights are digitally documented, preserving institutional knowledge for future teams. 
• Integrated Workflows: 24UP® can interface with enterprise asset-management (EAM) systems such as SAP PM or Maximo, ensuring maintenance coordination and visibility across departments. 

The Champion Advantage

A successful modernization doesn’t end at commissioning; it evolves into sustained performance. Champion’s 24UP® Solutions transforms traditional “break-fix” maintenance into a proactive lifecycle-management strategy that drives long-term value. 

By combining real-time visibility, cybersecurity vigilance, and continuous improvement, 24UP® helps organizations: 

• Extend asset life and reliability 
• Maintain compliance and security 
• Optimize performance and efficiency 
• Empower personnel through shared insight and training 

Modernization is sustained through performance, and Champion can help you achieve your goals, long after the project is complete.