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Does planned maintenance reduce the cost of unplanned downtime?
Balance avoided outage contribution and repair costs with planned downtime and preventive spend.
Example scenario
Editable demonstration inputs, not verified industry benchmarks. Enable JavaScript to calculate your own scenario.
- Unplanned failures / year
- 12
- Downtime hours / failure
- 8
- Expected failure reduction
- 40 %
- Contribution lost / constrained hour
- $1,000
- Repair cost / failure
- $2,500
- Extra planned downtime / year
- 16
- Annual maintenance program cost
- $25,000
Annual preventive-maintenance net benefit
Example result only, not a forecast or promise.
- Unplanned hours avoided
- 38.4
- Avoided repair cost
- $12,000
- Cost of additional planned downtime
- $16,000
What to do with this result
Use asset-level failure history and the production schedule; ensure avoided downtime could really have produced saleable output.
Know what is inside the model.
Planning model, not personalized financial advice. Your inputs remain in your browser.
Calculation method
Net benefit = failures × reduction × (downtime hours × contribution + repair cost) − planned downtime × contribution − preventive program cost.
Assumptions and limitations
- Example inputs are editable scenarios, not Aryo results or independently verified industry benchmarks.
- Recovered capacity is not booked revenue or automatic cash savings. Validate the bottleneck, quality and demand before monetizing output.