Predictive Maintenance ROI Calculator

Timeline Year 0
2021
PROJECT COST SAVINGS and/or INCOME
Decreased Helpdesk Support € -
Reduced Clerical Staff € -
Time Saved - Manual Creation of Reports € -
Annual Maintenance € -
Reduced Consumables € -
Cost Savings on Periodic Inspections € -
Cost Savings on Ad-Hoc Inspections € -
Cost Savings on Periodic Activities € -
Cost Savings on Ad-Hoc Activities € -
Cost Savings on Replacements € -
Revenue from increased production capacity € -
Revenue Increase on Energy Efficiency € -
… (Add rows if needed)
COST SAVINGS & INCOME € -

PROJECT INITIAL COST (One-time)

Initiation € -
Formulation of specifications and project plan € -
Marketing research of available platforms € -
Consultation costs € -
… (Add rows if needed) € -
Engineering & development € -
Basic design of solution € -
Testing of basic design € -
Detailed design of solution € -
Development costs € -
… (Add rows if needed) € -
Purchase & installation € -
Purchase hardware (sensors, connectors etc) € -
Purchase of software € -
Purchase of spare parts € -
Installation & connecting of sensors, cabling etc. € -
Set up measuring points, server etc € -
Provide infrastructure for streaming data € -
System configuration € -
… (Add rows if needed) € -
Transfer to organization € -
Setting up governance € -
 Synchronizing PdM procedures with logistics € -
Constructing of documentation, user manuals etc € -
Potential re-organization of teams € -
Training of personnel € -
… (Add rows if needed) € -
SELECTION COSTS € -

RECURRING COSTS
Software licenses € -
Database € -
Additional Licenses € -
Hardware € -
Network € -
System Configuration € -
Training € -
Contingency € -
… (Add rows if needed) € -
IMPLEMENTATION COSTS € -

OTHER LABOR COSTS

Annual Maintenance € -
Disaster Recovery € -
… (Add rows if needed) € -
ONGOING COSTS € -
ALL EXPENDITURES € -
BALANCE € -
CUMULATIVE BALANCE € -
DISCOUNT RATE
Interest rate %
Time factor 0
Equivalent Discount Factor 1
Discounted Balance € -
Cumulative Discounted Balance € -

PROJECT RESULTS
Project Income € -
Project Expenditure € -
Net Project Savings € -
ROI (Yearly) #DIV/0!
NPV € -
Overall ROI (After 6 years) #DIV/0!

Yearly Project Balance

 Yearly Project Balance

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Balance Cumulative Balance

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2022 2023 2024 2025

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#DIV/0! #DIV/0! #DIV/0! #DIV/0!
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Balance ROI
Balance ROI

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 Year 5 Year 6 Total
2026 2027

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#DIV/0! #DIV/0!
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ROI
 ROI

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3 4 5 6 7
Predictive Maintenance ROI Calculator

Cost Reduction Year 0

Timeline 2021
Periodic Inspections
Number of periodic inspections
Average cost of Inspection
Additional downtime required to perform inspections (hours)
Average cost of downtime per hour
Average Cost of Inspections per year (pre-PdM) € -
Estimated PdM inspection decrease factor 0.5
PdM adjusted # of inspections
PdM adjusted additional downtime
PdM Adjusted Average Cost of Inspections per year € -
Cost Savings on Periodic Inspections € -

Ad-Hoc Inspections
Number of ad-hoc inspections
Average cost of Inspection
Additional downtime required to perform inspections (hours)
Average cost of downtime per hour
Average Cost of Inspections per year (pre-PdM) € -
Estimated PdM inspection decrease factor 0.2
PdM adjusted # of ad-hoc inspections 0
PdM adjusted additional downtime 0
PdM Adjusted Average Cost of ad-hoc Inspections per year € -
Cost Savings on Ad-Hoc Inspections € -

Periodic Maintenance Activities

Number of periodic maintenance activities on average
Average cost of material/spare parts (per activity)
Average cost of labor (per activity)
Additional downtime required to perform activities (hours)
Average cost of downtime per hour
Average Cost of periodic activities per year (pre-PdM) € -
Estimated PdM activity decrease factor 0.5
PdM adjusted # of activities 0
PdM adjusted additional downtime 0
PdM Adjusted Average Cost of periodic acitivies per year € -
Cost Savings on Periodic Activities € -

Ad-Hoc Maintenance Activities

Number of ad-hoc maintenance activities on average
 Average cost of material/spare parts (per activity)
Average cost of labor (per activity)
Additional downtime required to perform activities (hours)
Average cost of downtime per hour
Average Cost of ad-hoc activities per year (pre-PdM) € -
Estimated PdM activity decrease factor 0.6
PdM adjusted # of activities
PdM adjusted additional downtime
PdM Adjusted Average Cost of ad-hoc acitivies per year € -
Cost Savings on Ad-Hoc Activities € -

Reduction of Replacement Costs

Average number of machinery needing replacement
Average cost of replacement
Additional downtime required to perform replacement (hours)
Average cost of downtime per hour
Average Cost of replacement per year (pre-PdM) € -
Estimated PdM replacement decrease factor 0.7
PdM adjusted # of replacements 0
PdM adjusted additional downtime 0
PdM Adjusted Average Cost of replacements per year € -
Cost Savings on Replacements € -
TOTAL COST REDUCTION € -
 Year 1 Year 2 Year 3 Year 4
2022 2023 2024 2025

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 Year 5 Year 6
2026 2027

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0 0
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Predictive Maintenance ROI Calculator

Revenue Increase
Timeline
Increased production capacity
Estimated increased equipment availability with PdM (hours)
Average units produced/processed per hour
Average selling price per unit
Revenue from increased production capacity

Increased energy efficiency

# machines running on non-optimal energy consuption mode
Average energy deficiency factor (%)
Average cost of energy kWh/year (per optimal machine)
Extra cost of running non-optimal energy consuption machines
Estimated PdM energy efficiency increase factor
PdM adjusted # of non-optimal energy consumption machines
Cost of running non-optimal energy consuption machines (PdM)
Revenue Increase on Energy Efficiency
TOTAL REVENUE INCREASE
 Year 0 Year 1 Year 2 Year 3
2021 2022 2023 2024

€ - € - € - € -

€ - € - € - € -
0.2
0 0 0 0
€ - € - € - € -
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 Year 4 Year 5 Year 6
2025 2026 2027

€ - € - € -

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0 0 0
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Predictive Maintenance ROI Calculator

Timeline Year 0
2021
PROJECT COST SAVINGS and/or INCOME
Decreased Helpdesk Support € 800.00
Reduced Clerical Staff € 1,000.00
Time Saved - Manual Creation of Reports € 500.00
Annual Maintenance € 8,000.00
Reduced Consumables € 3,000.00
Cost Savings on Periodic Inspections € 6,800.00
Cost Savings on Ad-Hoc Inspections € 3,740.00
Cost Savings on Periodic Activities € 15,150.00
Cost Savings on Ad-Hoc Activities € 18,960.00
Cost Savings on Replacements € 34,720.00
Revenue from increased production capacity € 50,000.00
Revenue Increase on Energy Efficiency € 1,200.00
… (Add rows if needed)
COST SAVINGS & INCOME € 143,870.00

PROJECT INITIAL COST (One-time)

Initiation € 13,000.00
Formulation of specifications and project plan € 2,000.00
Marketing research of available platforms € 1,000.00
Consultation costs € 10,000.00
… (Add rows if needed)
Engineering & development € 24,000.00
Basic design of solution € 5,000.00
Testing of basic design € 2,000.00
Detailed design of solution € 15,000.00
Development costs € 2,000.00
… (Add rows if needed)
Purchase & installation € 15,800.00
Purchase hardware (sensors, connectors etc) € 5,000.00
Purchase of software € 3,000.00
Purchase of spare parts € 2,000.00
Installation & connecting of sensors, cabling etc. € 500.00
Set up measuring points, server etc € 1,000.00
Provide infrastructure for streaming data € 4,000.00
System configuration € 300.00
… (Add rows if needed)
Transfer to organization € 6,000.00
Setting up governance € 1,000.00
 Synchronizing PdM procedures with logistics € 2,000.00
Constructing of documentation, user manuals etc € 1,000.00
Potential re-organization of teams
Training of personnel € 2,000.00
… (Add rows if needed)
SELECTION COSTS € 58,800.00

RECURRING COSTS
Software licenses
Database € 10,000.00
Additional Licenses € 1,000.00
Hardware € 50,000.00
Network € 10,000.00
System Configuration € 10,000.00
Training € 20,000.00
Contingency
… (Add rows if needed)
IMPLEMENTATION COSTS € 101,000.00

OTHER LABOR COSTS

Annual Maintenance
Disaster Recovery
… (Add rows if needed)
ONGOING COSTS € -
ALL EXPENDITURES € 159,800.00
BALANCE -€ 15,930.00
CUMULATIVE BALANCE -€ 15,930.00
DISCOUNT RATE
Interest rate % 5
Time factor 0
Equivalent Discount Factor 1.05
Discounted Balance -€ 15,930.00
Cumulative Discounted Balance -€ 15,930.00

PROJECT RESULTS
Project Income € 143,870.00
Project Expenditure -€ 159,800.00
Net Project Savings -€ 15,930.00
ROI (Yearly) -10%
NPV -€ 15,930.00
Overall ROI (After 6 years) 122%

Yearly Project Balance

€ 1,154

€ 784,487.00
 Yearly Project Balance

€ 1,154

€ 784,487.00

€ 599,233.00

€ 395,866.00 € 369,9

€ 208,069.00 € 187,797.00 € 203,367.00 € 185,254.00

€€112,488.00
96,558.00 € 111,511.00
-€ 15,930.00
1 2 3 4 5 6 7

Balance Cumulative Balance

 Year 1 Year 2 Year 3 Year 4
2022 2023 2024 2025

€ 21.00
€ 22.00 € 23.00
€ 3.00
€ 2.00 € 2.00 € 2.00
€ 4,584.00 € 3,806.00 € 4,452.00 € 5,036.00
€ 2,640.00 € 2,240.00 € 2,580.00 € 2,660.00
€ 12,200.00 € 7,600.00 € 14,150.00 € 37,150.00
€ 18,240.00 € 11,520.00 € 20,280.00 € 51,480.00
€ 70,000.00 € 45,920.00 € 68,320.00 € 153,440.00
€ 75,000.00 € 100,000.00 € 125,000.00 € 150,000.00
€ 1,800.00 € 2,400.00 € 3,000.00 € 3,600.00

€ 184,488.00 € 173,511.00 € 237,805.00 € 403,369.00

€ - € 2.00 € 2.00

€ 2.00 € 2.00

€ - € - € - € -

€ - € - € - € -

€ - € - € - € -
 € - € - € 2.00 € 2.00

€ 10,000.00 € 10,000.00
€ 2,000.00 € 2,000.00 € 50,000.00 € 100,000.00
€ 20,000.00 € 10,000.00 € 100,000.00
€ 10,000.00 € 10,000.00
€ 10,000.00 € 10,000.00 € 3.00
€ 20,000.00 € 20,000.00

€ 72,000.00 € 62,000.00 € 50,003.00 € 200,000.00

€ 3.00

€ - € - € 3.00 € -
€ 72,000.00 € 62,000.00 € 50,008.00 € 200,002.00
€ 112,488.00 € 111,511.00 € 187,797.00 € 203,367.00
€ 96,558.00 € 208,069.00 € 395,866.00 € 599,233.00

1 2 3 4

€ 107,131.43 € 101,143.76 € 162,226.11 € 167,310.53

€ 91,201.43 € 192,345.19 € 354,571.30 € 521,881.84

€ 184,488.00 € 173,511.00 € 237,805.00 € 403,369.00

-€ 72,000.00 -€ 62,000.00 -€ 50,008.00 -€ 200,002.00
€ 112,488.00 € 111,511.00 € 187,797.00 € 203,367.00
156% 180% 376% 102%
€ 107,131.43 € 101,143.76 € 162,226.11 € 167,310.53

Balance ROI

376%

€ 1,154,408.00

€ 784,487.00
Balance ROI

376%

€ 1,154,408.00

€ 784,487.00

€ 599,233.00
180%
156%
0 € 369,921.00
10
0 € 203,367.00 € 185,254.00

5 6 7
-10%
1 2 3 4 5
ulative Balance
 Year 5 Year 6 Total
2026 2027

€ 800.00
€ 1,021.00
€ 2.00 € 56.00 € 603.00
€ 25.00 € 8,028.00
€ 2.00 € 3,008.00
€ 5,800.00 € 7,440.00 € 37,918.00
€ 3,100.00 € 3,660.00 € 20,620.00
€ 22,050.00 € 39,450.00 € 147,750.00
€ 33,960.00 € 60,840.00 € 215,280.00
€ 141,120.00 € 253,680.00 € 767,200.00
€ 175,000.00 € 200,000.00 € 875,000.00
€ 4,200.00 € 4,800.00 € 21,000.00
€ -
€ 385,257.00 € 569,928.00 € 2,098,228.00

€ 3.00 € 3.00 € 13,010.00

€ 2,000.00
€ 3.00 € 1,007.00
€ 3.00 € 10,003.00
€ -
€ - € 4.00 € 24,004.00
€ 5,000.00
€ 2,000.00
€ 15,000.00
€ 4.00 € 2,004.00
€ -
€ - € - € 15,800.00
€ 5,000.00
€ 3,000.00
€ 2,000.00
€ 500.00
€ 1,000.00
€ 4,000.00
€ 300.00
€ -
€ - € - € 6,000.00
€ 1,000.00
 € 2,000.00
€ 1,000.00
€ -
€ 2,000.00
€ -
€ 3.00 € 7.00 € 58,814.00

€ 100,000.00 €
€ 100,000.00 €
€ 200,000.00 €
€ -
€ 30,000.00
100,000.00 € 355,000.00
100,000.00 € 380,000.00
€ 30,000.00
€ 30,003.00
€ 60,000.00
€ -
€ -
200,000.00 € 885,003.00

€ -
€ 3.00
€ -
€ - € - € 3.00
€ 200,003.00 € 200,007.00 € 943,820.00
€ 185,254.00 € 369,921.00 € 1,154,408.00
€ 784,487.00 € 1,154,408.00 € 3,222,691.00

5 6

€ 145,151.36 € 276,040.75 € 943,073.94

€ 667,033.19 € 943,073.94 € 2,754,176.89

€ 385,257.00 € 569,928.00 € 2,098,228.00

-€ 200,003.00 -€ 200,007.00 -€ 943,820.00
€ 185,254.00 € 369,921.00 € 1,154,408.00
93% 185%
€ 145,151.36 € 276,040.75 € 943,073.94

ROI

376%
 ROI

376%

180% 185%

102%
93%

3 4 5 6 7
Predictive Maintenance ROI Calculator

Cost Reduction Year 0

Timeline 2021
Periodic Inspections
Number of periodic inspections 25
Average cost of Inspection € 264.00
Additional downtime required to perform inspections (hours) 14
Average cost of downtime per hour € 500.00
Average Cost of Inspections per year (pre-PdM) € 13,600.00
Estimated PdM inspection decrease factor 0.5
PdM adjusted # of inspections 12.5
PdM adjusted additional downtime 7
PdM Adjusted Average Cost of Inspections per year € 6,800.00
Cost Savings on Periodic Inspections € 6,800.00

Ad-Hoc Inspections
Number of ad-hoc inspections 25
Average cost of Inspection € 300.00
Additional downtime required to perform inspections (hours) 14
Average cost of downtime per hour € 800.00
Average Cost of Inspections per year (pre-PdM) € 18,700.00
Estimated PdM inspection decrease factor 0.2
PdM adjusted # of ad-hoc inspections 20
PdM adjusted additional downtime 11.2
PdM Adjusted Average Cost of ad-hoc Inspections per year € 14,960.00
Cost Savings on Ad-Hoc Inspections € 3,740.00

Periodic Maintenance Activities

Number of periodic maintenance activities on average 15
Average cost of material/spare parts (per activity) € 1,200.00
Average cost of labor (per activity) € 500.00
Additional downtime required to perform activities (hours) 6
Average cost of downtime per hour € 800.00
Average Cost of periodic activities per year (pre-PdM) € 30,300.00
Estimated PdM activity decrease factor 0.5
PdM adjusted # of activities 7.5
PdM adjusted additional downtime 3
PdM Adjusted Average Cost of periodic acitivies per year € 15,150.00
Cost Savings on Periodic Activities € 15,150.00

Ad-Hoc Maintenance Activities

Number of ad-hoc maintenance activities on average 10
 Average cost of material/spare parts (per activity) € 1,600.00
Average cost of labor (per activity) € 600.00
Additional downtime required to perform activities (hours) 12
Average cost of downtime per hour € 800.00
Average Cost of ad-hoc activities per year (pre-PdM) € 31,600.00
Estimated PdM activity decrease factor 0.6
PdM adjusted # of activities 4
PdM adjusted additional downtime 4.8
PdM Adjusted Average Cost of ad-hoc acitivies per year € 12,640.00
Cost Savings on Ad-Hoc Activities € 18,960.00

Reduction of Replacement Costs

Average number of machinery needing replacement 5
Average cost of replacement € 8,000.00
Additional downtime required to perform replacement (hours) 12
Average cost of downtime per hour € 800.00
Average Cost of replacement per year (pre-PdM) € 49,600.00
Estimated PdM replacement decrease factor 0.7
PdM adjusted # of replacements 1.5
PdM adjusted additional downtime 3.6
PdM Adjusted Average Cost of replacements per year € 14,880.00
Cost Savings on Replacements € 34,720.00
TOTAL COST REDUCTION € 79,370.00
 Year 1 Year 2 Year 3 Year 4
2022 2023 2024 2025

12 8 11 23

12 11 12 8

€ 9,168.00 € 7,612.00 € 8,904.00 € 10,072.00

6 4 5.5 11.5
6 5.5 6 4
€ 4,584.00 € 3,806.00 € 4,452.00 € 5,036.00
€ 4,584.00 € 3,806.00 € 4,452.00 € 5,036.00

12 8 11 23

12 11 12 8

€ 13,200.00 € 11,200.00 € 12,900.00 € 13,300.00

9.6 6.4 8.8 18.4

9.6 8.8 9.6 6.4
€ 10,560.00 € 8,960.00 € 10,320.00 € 10,640.00
€ 2,640.00 € 2,240.00 € 2,580.00 € 2,660.00

12 8 11 23

5 2 12 44

€ 24,400.00 € 15,200.00 € 28,300.00 € 74,300.00

6 4 5.5 11.5
2.5 1 6 22
€ 12,200.00 € 7,600.00 € 14,150.00 € 37,150.00
€ 12,200.00 € 7,600.00 € 14,150.00 € 37,150.00

12 8 11 23
 5 2 12 44

€ 30,400.00 € 19,200.00 € 33,800.00 € 85,800.00

4.8 3.2 4.4 9.2

2 0.8 4.8 17.6
€ 12,160.00 € 7,680.00 € 13,520.00 € 34,320.00
€ 18,240.00 € 11,520.00 € 20,280.00 € 51,480.00

12 8 11 23

5 2 12 44

€ 100,000.00 € 65,600.00 € 97,600.00 € 219,200.00

3.6 2.4 3.3 6.9

1.5 0.6 3.6 13.2
€ 30,000.00 € 19,680.00 € 29,280.00 € 65,760.00
€ 70,000.00 € 45,920.00 € 68,320.00 € 153,440.00
€ 107,664.00 € 71,086.00 € 109,782.00 € 249,766.00
 Year 5 Year 6
2026 2027

25 45

10 6

€ 11,600.00 € 14,880.00

12.5 22.5
5 3
€ 5,800.00 € 7,440.00
€ 5,800.00 € 7,440.00

25 45

10 6

€ 15,500.00 € 18,300.00

20 36
8 4.8
€ 12,400.00 € 14,640.00
€ 3,100.00 € 3,660.00

25 45

2 3

€ 44,100.00 € 78,900.00

12.5 22.5
1 1.5
€ 22,050.00 € 39,450.00
€ 22,050.00 € 39,450.00

25 45
 2 3

€ 56,600.00 € 101,400.00

10 18
0.8 1.2
€ 22,640.00 € 40,560.00
€ 33,960.00 € 60,840.00

25 45

2 3

€ 201,600.00 € 362,400.00

7.5 13.5
0.6 0.9
€ 60,480.00 € 108,720.00
€ 141,120.00 € 253,680.00
€ 206,030.00 € 365,070.00
Predictive Maintenance ROI Calculator

Revenue Increase
Timeline
Increased production capacity
Estimated increased equipment availability with PdM (hours)
Average units produced/processed per hour
Average selling price per unit
Revenue from increased production capacity

Increased energy efficiency

# machines running on non-optimal energy consuption mode
Average energy deficiency factor (%)
Average cost of energy kWh/year (per optimal machine)
Extra cost of running non-optimal energy consuption machines
Estimated PdM energy efficiency increase factor
PdM adjusted # of non-optimal energy consumption machines
Cost of running non-optimal energy consuption machines (PdM)
Revenue Increase on Energy Efficiency
TOTAL REVENUE INCREASE
 Year 0 Year 1 Year 2 Year 3
2021 2022 2023 2024

10 15 20 25
25
€ 200.00
€ 50,000.00 € 75,000.00 € 100,000.00 € 125,000.00

10 15 20 25
0.15
€ 4,000.00
€ 6,000.00 € 9,000.00 € 12,000.00 € 15,000.00
0.2
8 12 16 20
€ 4,800.00 € 7,200.00 € 9,600.00 € 12,000.00
€ 1,200.00 € 1,800.00 € 2,400.00 € 3,000.00
€ 51,200.00 € 76,800.00 € 102,400.00 € 128,000.00
 Year 4 Year 5 Year 6
2025 2026 2027

30 35 40

€ 150,000.00 € 175,000.00 € 200,000.00

30 35 40

€ 18,000.00 € 21,000.00 € 24,000.00

24 28 32
€ 14,400.00 € 16,800.00 € 19,200.00
€ 3,600.00 € 4,200.00 € 4,800.00
€ 153,600.00 € 179,200.00 € 204,800.00