Estimate your savings
Give us 4 numbers. We'll size the deployment and show the annual avoided loss. Defaults benchmarked to Siemens, McKinsey, Deloitte and ABB public studies — see sources at the bottom.
Your inputs
Typical process-line asset loss
Benchmark · Oxmaint MTTR benchmark · Aberdeen
Override profile defaults (optional)
Annual loss you're carrying today
€1,125,000
30 assets × 2.5 incidents × 6 h × €2500/h
Estimated annual loss avoided
€562,500
Applying a 50% downtime reduction— the upper bound cited by McKinsey's 2020 predictive-maintenance study (10–40% maintenance-cost reduction, up to 50% less downtime). Deloitte's Analytics Institute reports 10–20% uptime improvement on comparable programs.
Investment range (indicative)
Where our defaults come from
The calculator's default downtime-cost and fault-frequency figures are anchored to publicly available studies from analyst firms, OEMs, and industry associations. You can override any field — or cite these sources directly to your finance team.
Siemens — The True Cost of Downtime 2024
Fortune 500 companies lose ~11% of annual revenue to unplanned downtime (vs 8% in 2019). Automotive: €2.1M/h. Heavy industry: 4× higher per hour than in 2019. SMB ceiling €150k/h.
McKinsey & Company — Predictive Maintenance (2020)
PdM programs cut unplanned downtime up to 50% and reduce maintenance costs 10–40% across process and discrete manufacturing.
Deloitte Analytics Institute — Predictive Maintenance Position Paper
Equipment uptime +10–20%, overall maintenance cost −5–10%, maintenance planning time −20–50%. Broad-industry analysis.
ABB — Value of Reliability Survey (2023)
Median unplanned downtime cost ~€115k/h across industrial sectors. Over two-thirds of respondents experience downtime at least monthly.
MaintainX — 2024 State of Industrial Maintenance
Cross-sector avg unplanned downtime cost €22k/h; up to €480k/h for larger facilities. 65% of teams cite proactive maintenance as the most effective downtime reducer.
Industry MTTR benchmarks (Oxmaint, SMRP)
Automotive assembly 1–3 h, food & beverage 2–4 h, chemical processing 2–6 h, mining 4–12 h, utilities 2–6 h per incident — used to anchor per-asset downtime-per-incident defaults.
USD→EUR conversions applied where the original study reported in USD. Per-asset cost-per-hour figures (€1,800–€5,800/h) are deliberately set below plant-wide medians to reflect loss on a single critical machine, not a full production-line stop.