Preventive Maintenance ROI Calculator
Weigh the cost of a preventive maintenance program against the breakdown and downtime cost it avoids, then read the ROI and payback. Your numbers stay in your browser.
Avoided failure cost per year
$0
How this is calculated
Each unplanned breakdown carries two costs: the direct repair, and the lost production while the line is down. The program earns its keep by removing some share of those breakdowns.
Payback (months) = PM cost ÷ (avoided cost ÷ 12)
What this deliberately leaves out
- Your reduction is an assumption. The slider is your expectation, not a guarantee. Preventive maintenance rarely removes every failure, and some failures are not age related.
- PM adds planned downtime and labor. The annual program cost should include technician hours, parts, and any planned stoppages, not just software or contracts.
- Averages hide spread. A single catastrophic failure can dwarf many small ones. Use costs that reflect your real distribution, not just the typical event.
- Divide by zero. If the PM cost is zero, ROI and payback are undefined, so the calculator shows avoided cost and net benefit only.
The value of one production hour should be contribution margin for that line, not full revenue. To size that downtime more precisely, use the downtime cost calculator; to turn failure and repair history into MTBF and MTTR, use the MTBF, MTTR and availability calculator; and to see the wider payback picture, try the manufacturing ROI calculator.
Make maintenance proactive, not reactive
Harmony connects your machines, systems, and paperwork into one real-time operational layer, no rip-and-replace, so the failures this calculator prices become visible before they stop the line. Read the CLS case study.
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