Maintenance Statistics

Maintenance planning requires solid data, much of which you’ll obtain by collecting information on your own operations. It also helps to know what’s happening in the industry as a whole—that way, your own metrics are compared within a larger context. This ultimately helps you gauge where your own maintenance management processes are. You’ll get an idea of where you’re doing well and where you might need to make improvements in terms of maintenance management.

In addition, these statistics show just how important modern technologies are in terms of improving operational reliability, no matter how well you’re doing in comparison with the industry overall.

Maintenance costs

  • Maintenance costs are estimated to range between 15% and 40% of total production costs (Dunn, 1987; Lofsten, 2000).
  • Exterior building maintenance costs about $0.03 per square foot for industrial buildings (BOMA, 2018).
  • Running a piece of equipment to the point of failure could cost up to 10 times as much as a regular maintenance program would (, 2018).
  • Every $1 worth of maintenance deferred could quadruple to $4 in capital renewal costs later on (Biedenweg).
  • Predictive maintenance is highly cost effective, saving roughly 8% to 12% over preventive maintenance, and up to 40% over reactive maintenance (according to the U.S. Department of Energy).

Types of maintenance

  • According to Plant Engineering’s 2018 maintenance survey, preventive maintenance is favored by 80% of maintenance personnel.
  • In the same survey, it was shown that usage of predictive maintenance had risen from 47% to 51%, and that running equipment to the point of failure had dropped from 61% to 57%.

Maintenance personnel

  • The median salary of an industrial maintenance technician came out to $50,440 in 2017 (Bureau of Labor Statistics).
  • The motor vehicle manufacturing industry pays the highest salary for maintenance technicians at $69,830 in 2017 (Bureau of Labor Statistics).
  • Maintenance technicians are most widely employed by the plastics manufacturing industry at 3,830 employees. The next runner up was motor vehicle parts manufacturing with 2,750 workers (Bureau of Labor Statistics).
  • First line supervisors of maintenance workers tend to earn more, averaging at $68,120 per year (Bureau of Labor Statistics).

Time management

  • Out of an average working day, only 24.5% of the average maintenance worker’s time is spent performing productive tasks (Plant Services, 2003).
  • Doing the math for an average maintenance technician based on average salary, the total time spent on unproductive tasks comes out to about $38,082 in labor costs per personnel per year.
  • An estimated 20.9% of wasted time results from travelling to different areas in the facility, with an additional 19.8% resulting from waiting for instructions (Plant Services, 2003).
  • Poor maintenance strategies can reduce a company’s production capacity by as much as 20% (Wollenhaupt, 2017).

Production downtimes

  • Roughly 82% of companies experienced at least one instance of unplanned downtime in the last three years (ServiceMax).
  • A 2005 survey published by Thomas Industry Update found that the average cost of unplanned downtimes in the automotive industry amounted to $22,000 per minute.
  • The average age of industrial assets in the United States is about 20 years, according to the Bureau of Economic Analysis. The number has grown significantly since 1990.
  • Aging equipment is the leading cause of unplanned downtimes at 50%, with lack of time coming in at 14%, according to a 2016 survey by Plant Engineering.

How to use the data

By comparing your own metrics to the data listed above, you can get a clearer idea of where your facility stands in terms of maintenance effectiveness.

For example, if your maintenance costs seem a little high compared to those listed above, there may be something amiss in your processes. You may be deferring maintenance too often, thereby allowing assets to age too much without regular upkeep, or you may have some inefficiency in personnel management.

It’s also important to note that a general trend may not necessarily apply to your situation. For instance, running equipment to the point of failure without regular maintenance can get expensive from a cost-effectiveness standpoint. However, if you already have aged assets at your site, you’ll need to compare the cost of replacement to that of maintenance. In some cases, an equipment upgrade could make more sense than performing additional repair work.

Ultimately, industrial data can help you make important decisions regarding your maintenance strategies, especially when combined with a thorough understanding of your own metrics.