What planned maintenance is worth, on your figures
Your plant
Nothing here is sent anywhere. The figures stay in your browser.
Your maintenance mix
The share of work that is unplanned today, and where you would like it to be. This is the only lever in the model — the saving is scaled by how much of your reactive workload actually gets retired.
Unplanned downtime, as it stands
288,000 MAD
96 production hours lost a year.
What the shift is worth, a year
15,223–22,834 MAD
A range, not a figure. The studies give a band and so does this.
| From downtime avoided | 4,937–7,406 |
|---|---|
| From maintenance spend | 10,286–15,429 |
| Reactive workload retired | 14% |
This is what moving to planned maintenance is worth, on published averages. It is not a claim about this product: no tool delivers the shift on its own, and the studies measure the practice, not the software.
Where every number comes from
A calculator on a vendor's own site is worth exactly as much as its stated assumptions, so here are ours. Each is a default you can overwrite above.
| Figure | Value | Source |
|---|---|---|
| Savings from a preventive programme against reactive-only work | 12%–18% | US DOE / PNNL, O&M Best Practices Guide, Release 3.0 |
| Ceiling for a facility heavily reliant on reactive work | 30%–40% | US DOE / PNNL, O&M Best Practices Guide, Release 3.0 |
| Target share of work left unplanned | 30% | US DOE / PNNL, O&M Best Practices Guide, Release 3.0 |
| Share of assets the average facility runs reactively | 35% | Plant Engineering, Maintenance Study |
| Cost of one hour stopped | Yours | No default. Published per-hour figures are drawn from Fortune 500 plants and are two or three orders of magnitude away from a site this size; using them here would produce an impressive number and a worthless one. |
What this deliberately does not model
The Department of Energy measured the practice of planned maintenance, not any particular piece of software. Software makes the practice possible to run; it does not deliver the saving by being installed. Anyone quoting you a percentage for their own tool is quoting you their marketing.
We have not set our pricing yet, so a payback period would be arithmetic on a number that does not exist. Tell us about your site and we will put a figure to it.
This counts lost hours at the rate you gave. It does not count scrapped material, missed delivery penalties, overtime to catch up, or the secondary damage a failure causes to the machine — all of which are real and none of which we can estimate for you.
Every percentage here is an average across surveyed facilities, most of them North American. Averages describe populations, not sites. Treat the output as an order of magnitude worth checking, not as a forecast.
Put your own figures in front of us
If the range above is worth the conversation, the next step is a look at your actual machine list and stoppage history rather than a spreadsheet of averages.