Decision Calculators

PM vs Run-to-Failure Cost Comparison Calculator

PM vs Run-to-Failure Cost Comparison Calculator takes the PM interval, PM labour and parts, your own observed failures per year with and without the PM, repair labour and parts, and downtime hours per failure and returns the annual cost of running a PM on each failure mode versus letting it run to failure, the difference, and a verdict. Cost per failure = repair labour × your burdened rate + repair parts + downtime hours × your downtime rate. With PM = (365 ÷ interval) × (PM labour × rate + PM parts) + your with-PM failure rate × cost per failure. Without PM = your without-PM failure rate × cost per failure. Both failure rates are counts from YOUR history, not a model. Nothing is pre-filled with an outside figure — no assumed failure rate, no reliability model, no claim that a PM prevents a failure. Every value on every sheet is one you entered or one computed from what you entered, against the As-of date you set on 1. Setup, never today's date.