Free maintenance strategy economics tool
Preventive vs Reactive Maintenance Cost Calculator
Compare run-to-failure with preventive maintenance using expected failures, repair cost, unplanned downtime, scheduled PM time, failure reduction and the value of production hours recovered.
Simple maintenance case
Failure Avoidance LedgerBuild the run-to-failure baseline
Asset population & baseline failures
Reactive failure consequences
Preventive-maintenance program
Program investment & horizon
Expected-cost logicReactive annual cost = expected failures × direct repair cost + unplanned downtime + entered failure consequences. Preventive strategy cost = scheduled PM labor/parts/planned downtime + annual program cost + the residual reactive failures after the entered failure-reduction assumption. The calculator does not assume that more PM automatically creates more reliability.
Planned vs Unplanned Hour Exchange
Physical hours, not dollar valueAre scheduled PM hours buying back more production time?
Maintenance Cost Bridge
From reactive exposure to preventive strategy cost
Failure-reduction sensitivity
How much reliability improvement does the PM program need?
| Failure reduction | Residual failures | Preventive strategy cost | Annual savings vs reactive | Net uptime recovered |
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Advanced maintenance portfolio
Maintenance Strategy QueueModel eight asset classes independently
Plant-wide economic assumptions
8 asset classes
Asset classQtyFailures / asset / yrRepair cost / failureDowntime hr / failurePM events / asset / yrDirect PM cost / eventPlanned downtime / eventFailure reduction
Advanced allocationThe annual plant program overhead is allocated across active asset classes in proportion to their direct PM program cost. Each class is then evaluated on its own preventive-versus-reactive economics, while portfolio totals preserve the shared overhead only once.
Maintenance Strategy Queue
Economics shown per classAsset classes ranked by reactive exposure
| Rank | Asset class | Baseline failures | Reactive annual cost | PM annual cost | Residual failure cost | Annual savings | Uptime recovered | Break-even reduction | Signal |
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Portfolio Hour Exchange
Unplanned downtime avoided versus planned PM time consumed
Downtime Cost × Failure Reduction
Cells show portfolio annual savingsAnnual savings stress matrix
Reliability improvement sensitivity
Portfolio economics as entered PM effectiveness changes
| Entered failure-reduction multiplier | Residual failures | Preventive annual cost | Annual savings | Net uptime recovered |
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Scope
Maintenance economics are only as good as the failure assumptions
This is an expected-cost planning model, not a reliability-engineering or safety determination. Use actual failure history, CMMS work orders, OEM recommendations, criticality analysis and maintenance records when setting failure rates and expected PM effectiveness. Some assets are appropriately run-to-failure; others require preventive, predictive or condition-based maintenance for reasons that are not captured by direct cost alone.