Preventive Maintenance Cost Calculator
See exactly how much your current reactive repair habit is costing you, and what a planned preventive maintenance budget would look like instead.
Preventive maintenance cost calculator inputs and results
Your Facility
Default: $1,200
Default: $250
Cost Comparison
Net fiscal recovery: $6,220 per year (22% reduction).
- Preventive program cost
- $12,500
- Optimized reactive cost (after 65% breakdown reduction)
- $10,080
The Classic 3:1 Rule of Reactive Repair Costs
Facilities teams have long observed that reactive repairs cost three to four times more than the same job done as planned, preventive work. The gap comes from a predictable set of cost multipliers: emergency callout fees for after-hours technicians, rush shipping surcharges on parts that would otherwise ship standard, secondary mechanical failure propagation (a seized bearing that takes out the motor housing with it), and the workflow disruption of unplanned downtime spreading beyond the asset itself.
A comprehensive PM program interrupts that cost chain before it starts. Industry data consistently shows that active, well-compliant PM routines cut emergency breakdown events by roughly 65% — which is the reduction factor built into the calculator above. The net result is rarely zero reactive spend; even the best-run programs still see some breakdowns. The goal is shrinking the reactive share of your budget while growing the planned, predictable share — which is exactly the comparison this calculator is built to show.