Business Case

ROI Calculator

Estimate your savings from predictive maintenance in under two minutes.

How to Use This

Enter Your Current Costs. See Your Potential Savings.

Based on real deployment data across manufacturing sectors. Fill in what you know - estimates are fine. Click Calculate to see your results.

Predictive Maintenance ROI Estimator

Fill in your operation details. Estimates are fine - you can refine later.

About Your Operation
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Your sector determines OEE improvement benchmarks and typical downtime cost ranges used in calculations.
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Small: up to 20 machines. Medium: 21-80. Large: 81-200. Enterprise: 200+. Used to scale benchmark estimates.
Your Annual Maintenance Costs
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Total wages and contractor fees paid to maintenance staff per year. Include overtime.
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Annual spend on replacement parts, consumables, lubricants, and maintenance materials.
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Lost production value from unplanned stoppages. Prefilled with your industry benchmark midpoint - adjust to your actual figure.
Don't know downtime cost? Estimate it:
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Total unplanned stoppage hours per year. Industry average across manufacturing is ~323 hrs/yr.
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Revenue or gross margin lost per hour of downtime. See the industry benchmark table below for reference ranges.
Equipment & Maturity
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Count of machines or assets you want Presage to watch. A machine may have multiple sensors - this is the asset count, not sensor count.
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Overall Equipment Effectiveness: the % of manufacturing time that is truly productive. World-class is ~85%. Most plants run 60-75%.
40%95%
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1 = mostly reactive, fixing things after they break. 10 = highly proactive, rarely surprised by failures. Most plants score 2-4.
ReactiveProactive
Your Estimated Results
Current Annual Maintenance Cost
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Labour + materials + downtime combined
Estimated Implementation Cost
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$500 per machine, no ongoing licensing fees
Projected Annual Savings
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Based on your maintenance maturity score
Year-One ROI
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Year-one savings vs. implementation cost
Projected OEE Improvement
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Based on industry benchmarks for your sector
Estimated Payback Period
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Time to recover implementation cost from savings
Conservative Year-One Recovery
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40% recovery rate - typical for first deployment year (DOE benchmark)

Downtime cost benchmarks derived from Siemens/Senseye True Cost of Downtime 2024 (n=181), ABB Value of Reliability Survey 2023 (n=3,215), and LNS Research 2023. Labour costs based on BLS Occupational Outlook Handbook May 2024 (median $63,510 + burden). Prefilled figures are starting-point estimates - adjust to your actual numbers. Actual results vary by plant, asset mix, and maintenance maturity. Talk to us for a site-specific assessment.

Reference Scenarios

What Other Plants Have Seen

S

Small Operation

10 machines. $400K annual maintenance spend.

1,940% ROI in year one

Implementation cost: $5,000. Annual savings: $68K+.

M

Mid-Size Plant

40 machines. $1.6M annual maintenance spend.

1,895% ROI in year one

Implementation cost: $20,000. Annual savings: $272K+.

L

Large Facility

120 machines. $5M+ annual maintenance spend.

2,608% ROI in year one

Implementation cost: $60,000. Annual savings: $850K+.

Ready to Go Further?

Get a Site-Specific Assessment

The calculator gives you a directional estimate. Book a call and we will give you a detailed analysis based on your actual assets and failure history.

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