Predictive Maintenance Calculator

Maintenance savings from IoT condition monitoring.

Number of assets

Failures/asset/year

Downtime per failure (hrs)

Downtime cost ($/hr)

Repair cost per failure ($)

PdM failure reduction (%)

Sensor cost per asset ($)

PdM platform ($/mo)

Tab to move between fields

Annual savings ($)

$822,000.00

≈ 20 Teslas

Current annual cost ($)$2,150,000.00

PdM annual cost ($)$1,328,000.00

ROI (%)5,871

Failures prevented/yr20

Payback period (months)0.1

How to Use This Calculator

Enter the number of assets to monitor and current failure rate (failures per asset per year).
Set average downtime hours per failure and downtime cost per hour (lost revenue + idle labor).
Enter average repair cost per failure and expected PdM failure reduction percentage.
Input sensor cost per asset and monthly PdM platform cost.
Review Annual savings, ROI (%), and Payback period (months) to justify the investment.

How the result changes with Failures/asset/year

Number of assets: Machines, motors, pumps, or equipment to monitor.
Failures/asset/year: Average unplanned failures per asset per year under current maintenance.
Downtime per failure (hrs): Average hours of production downtime per failure event.
Downtime cost ($/hr): Cost of production downtime per hour (lost revenue + idle labor).
Repair cost per failure ($): Average parts + labor cost for emergency repair.
PdM failure reduction (%): Expected reduction in unplanned failures with PdM. Industry avg: 30-50%.
Sensor cost per asset ($): Vibration, temperature, current sensors + installation per asset.
PdM platform ($/mo): Monthly cost for PdM analytics platform (cloud + ML processing).

Annual savings ($): Net annual savings from predictive maintenance vs current approach.
Current annual cost ($): Total annual cost of reactive/scheduled maintenance.
PdM annual cost ($): Total annual cost with predictive maintenance (including PdM investment).
ROI (%): Return on PdM investment (savings / investment cost).
Failures prevented/yr: Unplanned failures prevented annually by predictive maintenance.
Payback period (months): Months to recoup sensor hardware investment. -1 = no payback.

Identify Input Parameters
4 parameters
Number of assets = 20, Failures/asset/year = 2.5, Downtime per failure (hrs) = 8, Downtime cost ($/hr) = 5000 = 8 input(s) provided
Calculate Annual savings
Annual savings = currentTotalCostPerYear - pdmTotalCostPerYear
822000 = $822,000
Calculate Current annual cost
Current annual cost = downtimeCostPerYear + repairCostPerYear
2150000 = $2,150,000
Calculate PdM annual cost
PdM annual cost = pdmDowntimeCost + pdmRepairCostPerYear + pdmInvestmentAnnual
1328000 = $1,328,000