Home/Tools/Maintenance ROI Estimator
Maintenance ROI Estimator

Need to justify your maintenance?

Reactive · preventive · predictive — one asset.

What's the real cost of how you maintain this asset?

Inputs

Asset context, then reactive · preventive · predictive side by side.

Asset

Operating context

Derived: 4.0 failures/year

Maintenance strategies

Three alternative programs for the same asset — compare TCO, do not add them together.

Reactive — run to failure

Parts + labor + equipment.

Production loss

10%
Annual reactive — —

Preventive — calendar PM

≈ 4.1 PM visits / year

Parts + labor per stop.

Production loss per outage.

Effectiveness

45%
Annual preventive — —

Predictive — condition-based (CBM)

Continuous catches fast-developing failures; periodic rounds can miss them (detection capped at 80%).

Sensors, install, setup — one-time.

Routes, analytics, licenses.

Detection

80%

100% = every failure caught before it happens. Undetected failures still cost full price.

Adds visit + downtime from preventive column.

Annual predictive — —

Results

Verdict, annual TCO, and cost breakdown — updates as you type.

Annual cost comparison

Hover a bar segment to see what it includes.

Indicative estimate for one asset. Currency is unitless ($).

Long-term cost outlook

Cumulative TCO over your horizon — hover the curve to inspect any year.

Analysis horizon 10 years
1 yr 20 yr

Reactive Preventive Predictive

See your full results

Enter your details to unlock the verdict, annual cost comparison, and long-term outlook for this asset.

Want these numbers from YOUR data?

This estimator runs on assumptions. The Bad Actor Diagnostic runs on your real CMMS history: top 10 value destroyers, root causes, and a costed action plan – delivered in 3–4 weeks, from $7,000.